REHS2806-01
10 October 2008
Special Instruction
i02980244
Pandaros Digital Governor
Industrial Engine
4006 TRS GAS ( SG6)
4008 TRS GAS ( SG8)
4012-46A ( S12)
4016-61A ( S16)
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 ......................................................
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
2 SpeedMin1 and SpeedMin2 .......................... 18
3 SpeedMax1 and SpeedMax2 ........................ 18
4 Engine Stop ....................................................... 18
5 Switch or Impulse .......................................... 18
5 Close or Open ............................................... 18
5 Common Alarm ................................................. 18
5 Adjustment of PID parameters .............................. 18
6 PID Maps .............................................................. 19
10 Speed Ramps ....................................................... 20
10 Fixed Speed Ramp ........................................... 21
11 Programming example .................................. 21
11 Activation ....................................................... 21
11 Sectional Speed Ramp ......................................... 21
11 Programming Example ...................................... 23
11 Activation ........................................................... 23
11 System Wiring ....................................................... 23
11 External Connections Perkins Supplied Cable for
11 Diesel Engines ................................................ 25
12 External Connections and the Connector for the
13 Control Box for Diesel Engines ....................... 26
13 External Connections for Diesel Engines .......... 27
13 Cable Sizes ....................................................... 27
13 Alternative Connections for Speed Setting
13 Inputs ............................................................... 27
13 Single or Parallel Generator Variable Speed .. 27
14 Parallel Generator Heinzmann LSU/Sync ..... 28
14 Parallel Generator other LSU/Sync ............... 28
14 Wiring Diagram for the Digital Control Box in IP
14 Enclosure ........................................................ 29
14 Diagram for the Wiring Harness for 4006 and 4008
14 Diesel Engines ................................................ 30
15 Diagram for the Wiring for 4012 and 4016 Diesel
15 Engines ........................................................... 30
16 Diagram for the Wiring for 4006 and 4008 Gas
16 Engines ........................................................... 32
1
 Finding Faults .................................................... 34 The actuator is connected to the linkage of the fuel
Test 1 ............................................................. 34 injector on diesel engines in order to control the
Test 2 ............................................................. 34 amount of fuel. The actuator is connected to the
Test 3 ............................................................. 34 throttle valve on gas engines in order to control the
Test 4 ............................................................. 34 amount of fuel.
Test 5 ............................................................. 35
Test 6 ............................................................. 35 The control unit is engine mounted within an IP55
The governor lever moves when cranking the enclosure.
engine but the engine will not start (Diesel
Engines only) ................................................... 35
Test 1 ............................................................. 35
Test 2 ............................................................. 35
Test 3 ............................................................. 36
Test 4 ............................................................. 38
Test 5 ............................................................. 38
Governor moves to maximum position when power
supply is switched on. ..................................... 39
Test 1 ............................................................. 39
Test 2 ............................................................. 39
The engine goes to overspeed after starting ..... 39
Test 1 ............................................................. 39
Test 2 ............................................................. 39
Test 3 ............................................................. 40
The governor is not stable ................................. 40
Test 1 ............................................................. 40
Test 2 ............................................................. 40
Test 3 ............................................................. 40
Test 4 ............................................................. 40
Test 5 ............................................................. 41
Test 6 ............................................................. 41
Test 7 ............................................................. 41
Speed droops under load .................................. 41
Test 1 ............................................................. 41
Test 2 ............................................................. 41
Test 3 ............................................................. 42
Test 4 ............................................................. 42
The engine will not pull load .............................. 42
Error Codes ....................................................... 43
Error Memory .................................................... 46

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

2
System Overview

g01216812
Illustration 1
(1) Laptop computer (9) Load sharing (17) Mains parallel
(2) Control unit (10) Voltage matching (18) Island parallel
(3) Run status (11) Reactive load share (19) Group synchronizing
(4) CAN Communication (12) Speed ramp (20) Digital power control
(5) DC - Desk displays (13) Load ramp (21) Governor sensor
(6) Governor errors (14) Soft load transfer (22) Actuator
(7) Stop/Run (15) Isochronous ramp
(8) Synchronizing (16) Power factor set

3
 Note: A protection device for the external overspeed
NOTICE must always be used with the internal overspeed.
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 read 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.

A 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.

4
Diagram of the Governor System

g01216814
Illustration 2
(1) Switch inputs (5) Failure lamp (9) Pressure sensor
(2) Analog setpoint adjuster (6) Interface RS 232 (10) Temperature sensor
(3) Analog synchronizer (7) 24 V Power supply (11) Actuator that senses position
(4) Analog unit of measure for the load (8) Speed sensor (12) Actuator drive

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 to
• Maximum voltage (33 VDC) 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

5
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.

6
 g01216887
Illustration 3
(1) PC (2) Control box

1. Use the Perkins communication cable to 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.

7
 g01216892
Illustration 4

5. From the Adjustment – Actuator/Power Supply

screen, click on the Automatic adjust start button.

8
 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.

g01216949
Illustration 7

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.
Illustration 6
g01216921 Disconnect the PC cable.

7. The user will then be asked if the parameter 9. The actuator can now be installed to the engine
values should be stored in the control unit. The and the linkage connected.
user should select the option that states yes.

9
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 3.c to 6.
Illustration 8
1. Remove the lid of the IP55 box for the governor.
Remove the lid of the Pandaros box.
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.
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%.
5. Press the button (1). The system will automatically
calibrate the feedback.
10
g01216965
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.
6. Remove the 24 V supply. Replace the covers and
install the actuator to the engine.
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:
Speed Note: Any other changes to the configuration
require the use of the Service Tool and the special
• 1500 rev/min communication cable. Refer to the Service Tool
manual for information on other configurable
• 1800 rev/min parameters.

• 1500/1800 rev/min Changing the configuration of the

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.
External Input for Speed Control
governor
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.

Single generator fixed speed The various parameter settings for the engine modes
are detailed below.
The default configuration is Single Generator Fixed
Speed. The single generator has no provision for Note: After the parameters are changed, it is
parallel operation or speed control. The speed will be necessary to store the parameters in governor. Then
fixed at 1500 rev/min or 1800 rev/min. 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
This mode allows the Load Sharer input to be used screen for the service tool.
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.

11

Illustration 9
Single generator fixed 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.
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.
For single speed 1500 rev/min operation, the
parameter SpeedFix1 is used to set the engine
speed.
12
g01217756
For single speed 1800 rev/min operation, the
parameter number SpeedFix2 is used to set the
engine speed.
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.
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.
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 AnalogIn1_Refhi will set the highest value for the
type of analog input. The settings are shown below. analog input as an input that is valid. For an external
speed control for the potentiometer, this should be
• 0 to 5 volt input 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

Note: After selecting a different type of analog input, AnalogIn1_ErrorHigh sets the high input level when
the governor must reset for the change in order to an error will occur.
take effect.
AnalogIn1_Filter
The other available adjustments are detailed below.
AnalogIn1_Filter sets the filter level. It is not normally
AnalogIn1_RefLo necessary to change this value.

The AnalogIn1_RefLo will set the lowest value for The remainder of the settings on the screen
the analog input as an input which is valid. For an determine the value in the event of an error on the
external speed control for the potentiometer, this speed input. Store the last valid value or use a
should be set to 0. 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 The Load Control tab allows the setting of the input
and the inputs for the synchronizer are automatically parameters of the Analogue 1. The Synchronizer
set to the correct values and no other adjustments tab allows the setting of the input parameters of the
are required. Analogue 2.

Parallel generator other LSU/Sync
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.
Note: The range of the external speed control may
be limited by parameters SpeedMin and SpeedMax.
The parameters can be changed.
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 this mode, the Generator Mode must be set to For use with the digital load sharing or synchronizing
Parallel Operation and the LSU/Sync mode set to units, refer to the factory.
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 AnalogIn1_ErrorLow sets the lowest value at
input that is required to activate analog input 2. The which analogue 1 input signal will give as an
settings are listed below. error. If AnalogueIn1_RefLo was set at 0.5 volt,
AnalogIn1_ErrorLo could be set at 0.3 volt. This
• 0 to 5 volt input enables detection of an open circuit or faulty input
signal.
• 0 to 10 volt input
AnalogIn1_ErrorHigh
• 4 to 20 mA input
AnalogIn1_ErrorHigh sets the highest value at
AnalogIn1_RefLow which analogue 1 input signal will give as an
error. If AnalogueIn1_RefHi was set at 4.5 volt,
AnalogIn1_Reflow will set the lowest value that AnalogIn1_ErrorHi could be set at 4.7 volt. This
analog input 1 will allow as an input. enables detection of a faulty input signal.

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 AnalogIn2_RefLow will set the smallest value that
that is required by analog input 2. The settings are analog input 2 will accept as a valid input.
listed below.
AnalogIn2_RefHigh
• 0 to 5 volt input
AnalogIn2_RefHigh sets the highest value the analog
• 0 to 10 volt input input will accept as a valid input.

• 4 to 20 mA input

17
AnalogIn2_ErrorLow Common Alarm
AnalogIn2_ErrorLow sets the lowest value at Connect a 24 volt lamp to the output in order to
which the analog 2 input signal will give an indicate a fault with the governor.
error. If AnalogueIn2_RefLo was set at 0.5 volt,
AnalogIn2_ErrorLo could be set at 0.3 volt. This Adjustment of PID parameters
enables detection of an open circuit or faulty input
signal.
The engine is supplied with the governor PID
(Proportional, Integral and Derivative) gain
AnalogIn2_ErrorHigh
parameters. The PID will give a stable operation with
the majority of engine and alternator combinations.
AnalogIn2_ErrorHigh sets the highest value at When instability occurs with a particular combination
which the analog 2 input signal will give an
of engines and alternators, it will be necessary to
error. If AnalogueIn2_RefHi is set at 4.5 volt,
change the governor PID.
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

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.
• 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.
• Increase the I-factor Stability until the engine
operation alters to speed oscillations that have
longer waves.
• 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.
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.
PID Maps
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.
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.

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

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.
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.

• 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 • SpeedRamp1 - SpeedRampDown.
changing are determined by the parameters that are
listed below. Ramp rate for ramping downward in section 1

• 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 • SpeedRamp3 - SpeedRampUp.

are in the respective sections. The ramping ratesare
set via the following parameters. Ramp rate for ramping upward in section 3

• SpeedRamp1 - SpeedRampUp. • SpeedRamp - SpeedRampDown.

Ramp rate for ramping upward in section 1 Ramp rate for ramping downward 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 (3) Actuator
(2) Boost Pressure Sensor (if equipped) (5) Magnetic Pickup

24
External Connections Perkins Supplied
Cable for Diesel Engines
Illustration 18
• B+
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.
Note: When an overspeed fault occurs the supply
from the battery to the actuator and the stop solenoid
should be removed.
• B-
A negative 24 VDC is supplied from the battery to
the governor.
• 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.
• A3
A3 is common for synchronizer/load sharer input.
• B3
B3 is a input for the synchronizer. B3 may be
used for a control signal for speed from an analog
synchronizer.
• E3
25
g01237943
Load sharer input is for a connection to a Heinzmann
analog load sharing unit. For engines of a fixed
speed, no connection is required. E3 can be used
for other external speed control that can depend on
the configuration. For engines that are fixed speed,
no connection is required.
• 0V and 5V
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.
• 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
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.
• Alarm
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 CAN-
CAN 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 (3) Alarm lamp (5) CAN bus connections
(2) Run/Stop Switch (if equipped) (4) 1500/1800 switch (6) External analog controls

Cable Sizes Alternative Connections for Speed

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.
Setting Inputs
Single or Parallel Generator Variable Speed
Connect 0V and 5V to the potentiometer and the
slider of the potentiometer to E3.

27
 g01508540 g01507993
Illustration 21 Illustration 23
(1) 5k ten turn speed trim potentiometer (3) AT-01 Thesius with jumper set to digital

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.
Parallel Generator other LSU/Sync

g01507990
Illustration 22
g01238308
(1) Synchronizer SYG02 Illustration 24
(2) Load measuring unit LMG 10-01 (1) The external speed setting can be a voltage or a current.

28
Wiring Diagram for the Digital Control
Box in IP Enclosure

g01238312
Illustration 25
(1) CAN H (3) Temperature Sensor (5) Boost Sensor 4 - 20mA
(2) CAN L (4) Boost Sensor 0.5 - 4.5V

29
Diagram for the Wiring Harness for 4006
and 4008 Diesel Engines

g01248438
Illustration 26
(1) Control Box (5) Connector for the OEM (J3) Connector for the control box
(2) Boost Pressure Sensor (J1) Connector for the control box for the (J4) Actuator connector
(3) Actuator magnetic pickup (J5) Boost pressure sensor connector
(4) Magnetic Pickup (J2) Connector for the magnetic pickup

Diagram for the Wiring for 4012 and 4016

Diesel Engines

30
 g01248511
Illustration 27

31
(1) Relay RL2 (5) Control box (9) Connector for the OEM
(2) Relay RL1 (6) Actuator (10) Stop solenoid
(3) 3 pin Deutsch connector (7) Boost pressure sensor
(4) Start relay (8) Magnetic pickup

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

32
 g01248508
Illustration 28
Typical example of the wiring diagram for a 4008 gas engine

33
(1) Hall effect pickup (5) HT leads
(2) Magnets on the camshaft gear (6) Control box for the governor
(3) Ignition unit (7) Actuator or throttle valve
(4) Ignition coils (8) Magnetic speed pickup
Finding Faults
Note: The faults relate to problems with the governor
system. The faults are not mechanical problems with
the engine.
Test 1
The lever of the governor will not move to the run
position when the engine is cranked.
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.
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.
3. Operate the run/stop switch. The run/stop switch
is part of the panel for the OEM so details will vary.
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.
Result
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.
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.
Replace the lid of the control box.
STOP
Test 2
No DC voltage at control unit.
1. Remove the lid of the control box by removing
the 4 screws.
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.
The measurement should show at least 24 volts.
34
(9) Connector for the OEM
Result
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.
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.
If necessary, repair the components or replace the
components.
Replace the lid of the control box.
STOP
Test 3
Check the signal from magnetic pickup.
1. Disconnect the 2 pin plug from the pickup at the
control box.
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 engine cranking. The voltage should
be 1.5V AC at the A2/B2 plug.
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.
If the result is not OK, proceed to Test 4.
Test 4
Check the resistance at the control unit.
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.
Result
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”.
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.
STOP
Test 5
An error with the control box exists.
The error lamp will be illuminated.
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.
STOP
If the result is not OK, use Pandaros Packager
service tool to investigate the error. Otherwise
proceed to Test 6.
Test 6
Check the actuator..
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.
2. Turn off the 24 volts supply. Move the actuator
lever by hand in order to check free movement.
3. Remove the connecting plug from the actuator and
check resistance at terminals B/C. The resistance
should be approximately 2 ohm.
Result
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.
STOP
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.
STOP
The governor lever moves when cranking
the engine but the engine will not start
(Diesel Engines only)
Test 1
The stop solenoid is not energized (6 and 8
cylinder Diesel Engine only).
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.
Result
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.
If the result is not OK, proceed to Test 2.
Test 2
Check the voltage at the solenoid.
1. Remove the rubber boot from the stop solenoid in
order to reveal the connections.
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.
Result
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.
STOP
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
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 29.

36
 g01259965
Illustration 29
(1) RL2 (3) 3 pin Deutsch connector (5) The solenoid for the fuel stop is
(2) RL1 (4) Start relay energized in order to operate.

To start the engine, a 24 volt supply is initially put If the result is not OK, ensure that the 24 volt supply
onto pin B of connector J4. This will immediately is on. Use a multimeter on the DC voltage range
energize relay RL2. Both solenoids will be energized. across the coil of relay RL2. The reading should read
The first solenoid moves into position. The internal at least 24 volts.
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.

37
 g01260004
Illustration 30
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 If the result is not OK, the relay has failed. Replace
back through connector J4 to the control panel. If the relay and check that the solenoids are now
necessary, repair the component or replace the energized.
component.
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
Turn on the 24 volt supply. Select the DC voltage solenoids.
range on the multimeter. Use a multimeter to check
the voltage between each contact terminals. The 2. Locate the solenoid which has wire numbers 14
contact terminals are the large connections on the and 15. Wires 14 and 15 are connected to the
top of the relay. The wire numbers are 10 and 14. main terminals.
Test the voltage between the contacts and the battery
negative. Both the terminals should be 24 volts to
the battery negative.

38
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.
4. The solenoid should be energized. The solenoid
should be pulled in.
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.
Result
If the result is OK, proceed to test 6.
If the result is not OK, the solenoid is faulty. Replace
the solenoid and retest the solenoid.
STOP
Governor moves to maximum position
when power supply is switched on.
Note: Do not attempt to start the engine.
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.
Test 1
Inspect the wiring harness.
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.
Result
If the result is OK proceed to test 2.
If the result is not OK, repair the wiring harness. If
necessary, replace the wiring harness and retest the
wiring harness.
STOP
Test 2
Inspect the control box.
39
The internal power driver in the control box may
have failed. Replace the control box and retest the
equipment.
STOP
The engine goes to overspeed after
starting
The engine may overspeed due to incorrect as-
sembly or adjustment.
Engine overspeed could result in personal injury,
loss of life and/or property damage.
Be prepared to stop the engine by activating the
engine shutdown system or closing the air inlet
lines.
Test 1
Check the condition of the magnetic pickup.
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 not OK, there is a wiring fault or the
magnetic pickup is faulty. If necessary, repair the
components or replace the components.
Test 2
Check the parameters of the governor.
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 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.
3. Check the parameters.
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.
 b. The default gain on the adjustment screen is
12%.
c. The default stability on the adjustment screen
is 50%.
d. The default derivative on the adjustment screen
is 15%.
4. If the governor gain parameters are much lower
than the default values, enter the default values.
Retest the equipment.
Result
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, proceed to test 3.
Test 3
Replace the governor components.
Result
If the result is OK, STOP.
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.
STOP
The governor is not stable
Test 1
Check the signal from the magnetic pickup.
1. Disconnect the 2 pin plug from the pickup at the
control box.
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.
Result
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.
If the result is not OK, proceed to test 2.
40
Test 2
Check the resistance at the control unit.
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.
Result
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, 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.
2. Use the Pandaros Packager service tool.
Select Single Generator Fixed Speed on the
Configuration screen.
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.
Result
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.
If the result is not OK, return the engine configuration
to the previous setting and reset the governor.
Test 4
The governor gains are incorrectly set.
1. By using Pandaros Packager service tool, check
the parameters.
a. The default gain on the adjustment screen is
12%.
 b. The default stability on the adjustment screen
is 50%.
c. The default derivative on the adjustment screen
is 15%.
2. If the governor gain parameters are much lower
than the default values, enter the default values
and retest the equipment.
Result
If the result is OK, STOP.
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.
Result
If the result is OK, proceed to test 6.
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.
STOP
Test 6
Check the load fluctuations.
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.
Result
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.
41
If the result is not OK, proceed to test 7.
Test 7
Play or friction in linkage (Diesel Engines only).
Examine the linkage between the actuator and
injectors for any stiffness or excess play. If necessary,
repair the linkage or replace the linkage.
STOP
Speed droops under load
Test 1
The governor is set up for droop operation..
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.
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.
STOP
Test 2
The engine is being overloaded..
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.
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..

Replace the control box. Ensure that the settings in

the new box are correct and retest the engine.

STOP

The engine will not pull load

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

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

If the result is not OK, check the wiring to the boost

pressure sensor. If necessary, replace the sensor.

STOP

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 31.

42
 g01260016
Illustration 31

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

Code Name Value Description

3000 ConfigurationError 0 An error with the configuration file
3001 ErrPickUp 0 An error with the speed sensor
3004 ErrOverSpeed 0 Engine overspeed
3007 ErrLoadInput 0 Load sharer input error
3008 ErrSyncInput 0 Synchronizer input error
3009 ErrBoostPressure 0 Boost pressure sensor error
3012 ErrCoolantTemp 0 Not used
3032 ErrCoolantTempWarn 0 Not used
3050 ErrFeedback 0 Actuator feedback signal error
(continued)

43
(Table 3, contd)
3053 ErrActuatorDiff 0 The difference between the set
value of the actuator and the
actual value of the actuator is too
big.
3056 ErrFeedbackRef 0 Error on reference value of the
feedback of the actuator
3059 ErrFeedbackAdjust 0 Error during auto calibration of
actuator
3076 ErrParamStore 0 Error on storing parameters
3077 ErrProgramTest 0 Error on programming checksum
3078 ErrRAMTest 0 Error during RAM test
3080 ErrDisplay 0 Not used
3081 Err5V_Ref 0 Error on 5 volt reference
3085 ErrVoltage 0 Error on voltage supply
3090 ErrData 0 Error on data block
3092 ErrConfiguration 0 Configuration error
3093 ErrStack 0 Error of internal management of
the parameter
3094 ErrIntern 0 Internal software fault
3101 SErrPickUp 0 Sentinel for an error on the speed
sensor
3104 SErrOverSpeed 0 Sentinel for Engine overspeed
3107 SErrLoadInput 0 Sentinel for Load sharer input
error.
3108 SErrSyncInput 0 Sentinel for an error with the
input of the synchronizer
3109 SErrBoostPressure 0 Sentinel for an error with the
boost pressure sensor
3112 SErrCoolantTemp 0 Not used
3132 SErrCoolantTempWarn 0 Not used
3150 SErrFeedback 1 Sentinel for the error for the
actuator feedback signal
3153 SErrActuatorDiff 0 Sentinel for the difference
between the set value of the
actuator and the actual value of
the actuator is too big.
3156 SErrFeedbackRef 0 Sentinel for the error on reference
value of feedback for the actuator
3159 SErrFeedbackAdjust 0 Sentinel for Error during auto
calibration of actuator
3176 SErrParamStore 0 Sentinel for the error on storing
parameters
3177 SErrProgramTest 0 Sentinel for the error on
programming checksum
3178 SErrRAMTest 0 Error during RAM test
3180 SErrDisplay 0 Not used
3181 SErr5V_Ref 0 Sentinel for the error on 5 volt
reference
(continued)

44
(Table 3, contd)
3185 SErrVoltage 0 Sentinel for the error on voltage
supply
3190 SErrData 0 Sentinel for the error on the data
block
3192 SErrConfiguration 0 Sentinel for the error on the
configuration
3193 SErrStack 0 Sentinel for the error of the
management of the internal
parameters
3194 SErrIntern 0 Sentinel for the internal software
fault
3195 SExceptionNumber 0 Sentinel for the exception number
3196 SExceptionAddrLow 0000Hex Sentinel for the software fault
3197 SExceptionAddrHigh 0000Hex Sentinel for the software fault
3198 SExceptionFlag 0000Hex Sentinel for the software fault

The current errors are displayed by selecting Error

– Current Errors from the top menu of Pandaros
Packager. Refer to illustration 32.

g01238737
Illustration 32

The current error screen is then displayed. Refer to

illustration 33.

45
 g01260308
Illustration 33

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.

46
 g01238433
Illustration 34

47
©2008 Perkins Engines Company Limited Printed in U.K.
All Rights Reserved