SDG865 05-02-18 Operation Manual Service Version 3

Document: Operation Manual
Version: Service-3
Status: actual
SDG-865-01-01
Author: bs Date: 05-02-18 Smart Digital Governor HUEGLI TECH LTD
Engine SWITZERLAND
Governing Approved: MR Date: 05-02-18 for Bosch VP44 Pump Tel.:+41-62-916 50 30

Systems File: PC on MAN D0836 Series Fax.+41-62-916 50 35
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Operation Manual
Service Version
The SDG865 digital control unit (MSG)

communicates via CAN bus to the Bosch
VP44 Pump control unit (PSG).
The SDG provides all the necessary

signals and messages to interface with
the fuel pump.
1. Safety Instructions and Warnings
Please read this manual before installing and commissioning the system. It
contains important information about safety, use and maintenance of the system.
For information about the engine or the Bosch VP44 pump please refer to the
related literature.
For damage, which is caused by neglecting instructions, misuse or wrong

operation, all warranty will be rejected.
W:\DOKUMENTATION 2\Geräte\G A C\Governors\S D G\Applications\MAN-VP44\Manual\SDG865-05-02-18-Operation Manual-Service Version-3.doc Page 1 of 18

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Content:
1. Safety Instructions and Warnings ................................................................................1

2. Configurable Parameters ............................................................................................3
3. Specifications ...........................................................................................................4
4. Installation and Wiring ...............................................................................................5
5. Inputs and Outputs....................................................................................................6
6. Support Tools..........................................................................................................6
7. Keypad Functions......................................................................................................7
7.1 Overview...........................................................................................................7
7.2 Accessing SETUP mode.......................................................................................8
7.3 Accessing Functions ...........................................................................................8
7.4 Entering 4-digit Numbers .....................................................................................8
7.5 Entering %-Values ..............................................................................................8
7.6 Bar Graph Display & Flash Codes ..........................................................................9
8. Setting of adjustable Parameters: ..............................................................................10
8.1 Flywheel Teeth.................................................................................................10
8.2 Overspeed .......................................................................................................10
8.3 Crank Termination Setting .................................................................................10
8.4 Speed Settings .................................................................................................10
8.5 Fixed Speed Operation ......................................................................................10
8.6 Variable Speed Operation...................................................................................11
8.7 Starting Fuel Ramp Control ................................................................................12
8.8 Starting Fuel Preset Point...................................................................................12
8.9 Speed Ramping Control: ....................................................................................12
8.10 Droop Setting...................................................................................................12
8.11 Auto-Droop Enable............................................................................................12
8.12 GAIN ..............................................................................................................12
8.13 Stability...........................................................................................................12
8.14 Derivative ........................................................................................................12
9. Setting of Maps ......................................................................................................13
9.1 Gain points ......................................................................................................13
9.2 Max Setpoint Injection Mass (ME):......................................................................13
10. Saving the SDG Settings..........................................................................................13
10.1 Saving the Settings...........................................................................................13
10.2 Dismissing of inapplicable Settings......................................................................13
10.3 Factory Default Setting Recall ............................................................................14
11. Fault Handling .....................................................................................................14
11.1 General ...........................................................................................................14
11.2 Fault Log Read & Clear Options ..........................................................................14
11.3 Fault Code Table ..............................................................................................15
11.4 Trouble Shooting ..............................................................................................16
12. Dimensions .........................................................................................................18

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2. Configurable Parameters
Parameter Access Accessibility for Service Operator Access Description
Via Keypad via: see point:
Menu Key SmartView Keypad Keypad only
1)
Safety Parameters
Password for keypad - - - Not shown 6356 7.2
2)
Flywheel teeth 0 5 R+W R+W R 8.1
Overspeed limit 1 5 R+W R+W R 8.2
Fuel Injection Parameters
ME setpoint adjust 1 3 R R+W - 9.2
ME setpoint range - - R - -
PID-Parameters
Gain (8-point map) 0 1 R+W R+W R+W 9.1
Stability 0 2 R+W R+W R+W 8.13
Derivative 0 3 R+W R+W R+W 8.14
Start Parameters
Crank termination 2 7 R+W R+W R 8.3
Start fuel begin point 1 6 R+W R+W R+W 8.8
Start ramp 0 6 R+W R+W R+W 8.7
Speed Parameters
Fixed speed settings 0 4 R + W R + W R 8.5
Droop for fixed speeds 1 4 R + W R + W R + W 8.5, 8.10
Variable speed hi limit 0 7 R + W R + W R + W 8.6
Variable speed lo limit 1 7 R + W R + W R + W 8.6
Droop f. variable speed 1 4 R + W R + W R + W 8.6, 8.10
Speed ramp acceleration 0 9 R + W R + W R + W 8.9
Speed ramp deceleration 1 9 R + W R + W R + W 8.9
Information
Software version 3) R R R 7.2
SDG Serial number - - - - -
Software Built date - - - - -
Engine number 4) R - -
Run time hour counter - - R - -
Fault log read out 0 8 R R R 11.2
Fault log clear 1 8 yes yes no 11.2
Create report with - - no no no
password
Create report without - - yes no no
passw.
Factory Settings
Reset to default config. 1-2-3-4 yes yes yes 10.3
Notes:
R Read only permitted
R+W Read and write permitted
1) SmartView, Service version. GAC configuration and monitoring software.
2) Engine specific password, not published.
3) Software version is flashed out after entering correct password.
4) Engine number issued by MAN

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3. Specifications
Physical:
Dimensions 96 x 141 x 37 mm
Weight 0.64kg
Mounting Direct engine frame mounting,
isolated via rubber elements,
vertical mounting preferred, or in panel.
Performance:
Isochronous Operation / Steady State Stability ±0.25% or better
Speed Range of Governor 400 – 8000 Hz
Speed Drift with Temperature ±1% maximum
Environmental:
Ambient Operating Temperature Range -40o to 85 oC
Relative Humidity up to 95%
Input / Output Parameters:

Supply 24 VDC battery systems (19 to 33 VDC)
Polarity Negative Ground (case isolated)
Power Consumption 70 mA max. continuous
Speed Sensor Signal (MSP) 1 to 120 V RMS
Discrete Alarm Output 200 mA @ 24V
Auxiliary Input 5 VDC, for GAC/ComAp Synchr. & Load Sharer
Configuration Parameters:
Flywheel Teeth Range 50 – 250 teeth
Overspeed Setting 400 –10000 Hz *
Crank termination 50 – 1000 Hz *
Fixed Speed settings (all 3 speeds) 400 – 8000 Hz *
Variable Speed settings 400 – 8000 Hz *
Start Fuel Ramp 0 – 100%
Start Fuel Preset 0 – 100% (max fuel)
Droop Range 0 – 10% regulation
Speed Ramp up 0 – 100%
Speed Ramp down 0 – 100%
Reliability:
Vibration 7G @ 20-100Hz.
Testing (100%) Functionally tested
Password Protection:
Password 4-digit number
Notes: *) Speed values in RPM are based on the number of flywheel teeth.
RPM = Pickup frequency x 60 / flywheel teeth. (Max. frequency is 10'000 Hz.)

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4. Installation and Wiring
• Battery connections to terminals A and B cable is strictly required. Connect the shield
should be 2,5 mm2 , twisted or shielded. to terminal A.
• Battery positive (+) input, Terminal B should • The shields should be insulated to insure that
be fused for 10 Amps as illustrated in the no part of it comes in contact with engine
diagram. ground, otherwise, stray signals may be
• The governor should be mounted isolated introduced into the SDG causing erratic
from engine ground. operation.
• The Magnetic Speed Sensor cable to • For specific speed configuration using
terminals H and I MUST BE SHIELDED (or terminals J and K, please see table 1.
twisted) for its entire length. The shield
should only be connected to terminal A or N.
• The cables to the Variable Speed
Potentiometer can be of any reasonable
length up to 10 m. A shielded or twisted

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5. Inputs and Outputs

Battery Supply (24VDC) A–, B+ Shutdown must be triggered to command a
The SDG865 is running at 24VDC. shutdown.
Speed Pickup H, I This input determines how the critical faults

The SDG865 requires that the speed pickup be affect engine operation. Please refer to the Fault
present for engine operation. The SDG865 is Handling section for more information.
comparing the speed signal form the VP44 to its
own speed signal. If there is speed indicated by Alarm Driver (200mA Sink) S
the VP44 and not by the SDG865, then the This Driver allows the connection of a Horn,
SDG865 determines the speed signal as fault and Lamp, or slave relay (not exceeding 200mA).
logs fault 0201. This signal is activated anytime a fault is
detected. This driver is overload protected. If
MAB – Solenoid valve shut-off signal L tripped due to overload or short circuit, the unit
(VP44 signal) power must be reset to reset the circuit.
This is a VP44 signal and should not be tapped
into or tampered with. If low, the VP44 is 6-Pulse timing signal input from Engine Crank
allowed to operate. If high (battery +), the Shaft U, V
VP44 will shut off preventing the engine to run. This input gathers crank shaft timing pulses from
a special 6 tooth disk. The SDG865 conditions
LSS – Load Sharing and Synchronizing Input M this pick up signal and retransmits it out to the
Standard GAC interface. VP44 as the DZG signal.
Extra Ground connection for Wire Shields N DZG – Crankshaft speed Pulse W
The SDG865 allows an extra ground connection This is a signal required by the VP44 unit for
on the secondary terminal strip. This helps in the injection timing information. The VP44 will run
connection of extra grounds such as cable without this signal but engine performance may
shields and so forth. be poor.
Remote Shutdown Input Q CAN bus connections X, Y

(Emergency Stop, E-Stop) This connection allows the VP44 and the
This input must be latched to battery + to allow SDG865 to share information. The protocol is
the engine to run. If anytime this switch proprietary to the VP44. If this connection is
(connection) is opened the engine will be lost the engine will reduce power and shut off
commanded to shutdown by zero fuel and a within 2 seconds.
MAB signal that is high.
Internal / External (Emergency Stop) enable R

When this input is open, the SDG865 will be in 6. Support Tools
normal operation. This means the SDG865 will
follow the appropriate action required in the Fault SmartView Configuration and Monitoring
Finding Chart. Basically this means all shutdown Software
signals are active.
GAC’s SmartView specific edition for VP44
When this input is connected to battery +, the application takes advantage of the SDG865
SDG865 will not shutdown for critical faults. features. Please refer to the separate document
Only Overspeed will be monitored. Remote SmartView II.

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7. Keypad Functions
7.1 Overview
GAIN LED Numeric keys

Lit when for entering 4-digit numbers
- engine is running (ENTER has to be pressed after
- GAIN parameter typing in the number)
accessed in SETUP mode
RUN/SETUP LED
STABILITY LED Lit when SDG powered
Flashing Flashing in SETUP mode
- if no CAN communication.
Lit when
- STABILITY parameter
accessed in SETUP mode Diagnostics port
FAULT LED
DERIVATIVE LED A RUN / Lit when fault is detected before
Lit when GAIN
B
SETUP engine start.
- engine is cranking STABILITY FAULT Flashing when fault is detected
- DERIVATIVE parameter
C
DERIVATIVE when engine is running.
accessed in SETUP mode
D 10 1 2 3
9
E MENU button
8 4 5 6 for accessing:
LED BAR: indicating: F 7 - the menus in SETUP mode
- analogue (%) values 6 - GAIN point in GAIN map
- selected menu in SETUP G 5 7 8 9
- selected point in GAIN map
4
H MENU
flashing out 4-digit numbers 3 0 + SETUP button
I 2 SETUP for accessing SETUP mode
1 _ press and hold until RUN/SETUP
J ENTER
0 RUN
LED is flashing
K
L
RUN button
when exit SETUP mode and
save settings:
M N O P Q R S T U V W X Y
press and hold until RUN/SETUP
LED stops flashing
+ / - ARROW keys
for changing analogue (%) values
ENTER button
for activating 4-digit numbers Note: Do not press ENTER when
entered by the numeric keys changing values by the arrow
keys.

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7.2 Accessing SETUP mode The Bar Graph display will indicate which
menu is active (0, 1 or 2).
a) To access the SETUP mode press and b) Next press the particular key to access its
hold the SETUP button until RUN/SETUP function.
LED flashes. For example, press [MENU] [MENU] [5] to
b) Now enter the 4-digit security code access overspeed.
followed by the ENTER key. Note:
Each time a key is pressed the
Bar Graph LEDs will flash.
7.4 Entering 4-digit Numbers
c) If the proper security code has been Settings defined as 4-digit numbers are modified
entered, the Bar Graph LEDs will begin by typing in a 4-digit number followed by the
to flash out the 4-digit software version enter key. These values are flashed out by the
number. If not, repeat step b. four digits on the bar graph. Note: a 3-digit
d) The RUN/SETUP LED will always be number has to be typed in with a 0 (125 =[0]
flashing while the SDG is in the SETUP [1] [2] [5] ).
mode. If you have problems during the
configuration always check to make sure 7.5 Entering %-Values
this LED is flashing indicating you are in
SETUP mode. Settings defined as %-values are modified by
pressing the arrow keys [+] or [-]. You may
7.3 Accessing Functions have to press the arrow key several times to
illuminate the next LED. To set a defined value of
a) Once in the SETUP mode, the functions for example 30% press the [+] key until the LED
listed under each key can be accessed by 3 is on. If only LED 0 is on, this indicates the
using the MENU button. Each time the MENU value is between 0 and 9 %.
button is pressed, the next menu will become
active. Press until the desired menu is active.
A
RUN /
GAIN
SETUP
B STABILITY FAULT
1 2 3
DERIVATIVE
C
D 10 1 2 3
9
E
8
GAIN STABILITY DERIVATIVE MENU 0 7
4 5 6
MENU 0
F
6
- - ME SET POINT MENU 1 G
H
5
4
7 8 9
MENU
3 0 +
- - - MENU 2 I 2
1
SETUP
_
J ENTER
0 RUN
4 5 6
FIXED SPEED FLYW.TEETH START RAMP MENU 0
DROOP OVERSPEED START FUEL MENU 1
- - - MENU 2
A
RUN /
GAIN
SETUP
B STABILITY FAULT
DERIVATIVE
7 8 9
C
D 10 1 2 3
9
E
8 4 5 6
VAR.SP.HI-LINIT FAULT RETRIEVE SP.RAMP ACCEL. MENU 0 7
MENU 1
F
6
G 5 7 8 9
VAR.SP.LO-LIMIT FAULT LOG CLEAR SP.RAMP DECEL. MENU 1 H
4
3 MENU
0 +
CRANK TERM. - - MENU 2 I 2
1
SETUP
ENTER
_
J 0 RUN
MENU
0 +
A
SETUP
RUN /
GAIN
SETUP
B STABILITY FAULT
DERIVATIVE
C
_
D 10 1 2 3
9
E
8 4 5 6
7
MENU 2
F
ENTER G
6
5
4
7 8 9
RUN
H MENU
3 0 +
I 2 SETUP
1 _
J ENTER
0 RUN

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7.6 Bar Graph Display & Flash Codes
Bar Graph Display

The Bar Graph displays the “approximate” percentage from 0 to 100%. Pressing the +/- arrow
buttons, increases or decreases the value. You may have to press the +/- button several times
to illuminate the next LED. This is due to the difference in resolution between the LEDs and the
actual parameter being adjusted.
10
9
8
7 This indicates the value is
If only LED 0 is on, 6 between 50% and 59%.
the value is between
5
0% and 9%.
4
3
2
1
0
EXAMPLE 1 – Bar Graph displaying between 50% and 59%.
Code Flash Mode

All SDG values that are flashed out are always 4 digits. The LEDs are labeled as 0, 1, 2,..,10.
Code Flash mode can display any value between 0 and 9999. They would be displayed by
flashing 0-0-0-0 thru 9-9-9-9 respectively. Please review the example below of displaying the
value 1500.
10 10 10 10 10 10
9 9 9 9 9 9
8 8 8 8 8 8
7 7 7 7 7 7
6 6 6 6 6 6
5 5 5 5 5 5
4 4 4 4 4 4
3 3 3 3 3 3
2 2 2 2 2 2
1 1 1 1 1 1
0 0 0 0 0 0
all 1 5 0 0 all
EXAMPLE 2 – Code Flash mode displaying the number 1500.

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8. Setting of adjustable Parameters:
8.1 Flywheel Teeth

This parameter has to be set at the beginning, because all other digital numbers are
calculated on base of the number of flywheel teeth.
MENU 5
If the flywheel teeth number is set afterwards all speed related settings have to be
readjusted.
Entering menu 0, key 5, the set value is being flashed out.
Typing in a 4-digit number followed by pressing the enter key will change the
setting.
Now the new value is being flashed out.
8.2 Overspeed
The overspeed set point is used for engine protection.
MENU MENU 5
setting.
8.3 Crank Termination Setting

This set point helps the SDG determine if the engine is cranking or running.
When engine speed exceeds the crank termination setting the governor switches
MENU MENU MENU 7
from start up procedure to PID loop control.
setting.
8.4 Speed Settings

The SDG offers a variety of speed settings to the user. The user can select
from three fixed speed settings and one variable speed setting.
(see table 1 next page)
The variable speed input can be used as if it were a fixed speed. Any speed in-
between low and high idle adjusted on the potentiometer is reflecting a PID
controlled speed.
8.5 Fixed Speed Operation

Speed settings have to be made with the corresponding connections to terminal K
MENU 4 or/and J, wired up and switched before configuration.
Entering Menu 0, Key 4 the set value assigned to the selected speed is being
flashed out. Typing in a 4-digit number followed by pressing the enter key will
change the setting. Now the new value is being flashed out.
MENU MENU 4
Droop settings for the particular fixed speed are made similarly but here the values
are modified by using the arrow keys.

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8.6 Variable Speed Operation

Speed trim is automatically enabled when a 5kΩ potentiometer is connected to
Terminals E, F & G.
Speed trim is disabled by connecting a jumper between Terminals A and E.
Make sure the potentiometer is attached as shown on the wiring diagram.

The setting procedure also serves as alignment of the potentiometer.
Proceed as follows:
MENU 7 High speed

Turn the potentiometer such that maximum voltage is present on terminal E.
Access menu 0, key 7. The max. voltage is verified by the bar graph display. This
state also is recognized by the SDG as the potentiometers maximum position.
Typing in the 4-digit number followed by pressing the enter key will assign the
max. speed value (high idle) to this highest potentiometer position.
This max. value is now flashed out with the bar graph LEDs.
Low speed
Turn the potentiometer such that minimum voltage is present on terminal E.
Access menu 1, key 7. The min. voltage is verified by the bar graph display. This
MENU MENU 7
state also is recognized by the SDG as the potentiometers minimum position.
Typing in the 4-digit number followed by pressing the enter key will assign the
min. speed value (low idle) to this lowest potentiometer position.
This min. value is now flashed out with the bar graph LEDs.
Droop setting for variable speed is made with no connections on terminals J and K,
MENU MENU 4 the values are modified by using the arrow keys.
B (Battery +) to Jumper betw.

Connections Potentiometer
A (-) and E
K+J K J -
Speed [rpm] nstatic1 nstatic2 nstatic3 nvar
Droop [%] 0 0 0 0 yes no
Trim [rpm] 0 0 0 nvar,min
Droop no yes
Droop Droop 1 Droop 2 Droop 3
„variable“
Trim [rpm] ±100 ±100 ±100 nvar
Droop no no
Droop Droop 1 Droop 2 Droop 3
„variable“
Trim [rpm] 0 0 0 nvar,min
Table 1 - Speed Select Chart

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Additionally, there is a group of parameters that do not necessarily need to be preset for basic engine
operation: Starting Fuel and Speed Ramping.
8.7 Starting Fuel Ramp Control

This parameter gradually increases the amount of fuel during the engine start cycle,
MENU 6 which eliminates unnecessary smoke. The higher the setting the longer it takes to
reach full fuel delivery.
8.8 Starting Fuel Preset Point

MENU MENU 6 Determines how much fuel to begin with before fuel ramping engages.
8.9 Speed Ramping Control:

MENU 9 UP: Provides acceleration ramping during RPM input changes.
MENU MENU 9 DOWN: Provides deceleration ramping during RPM input changes.
8.10 Droop Setting

Each of the three fixed speed settings as well as the variable speed setting has a
MENU MENU 4
corresponding droop setting.
The settings have to be made with corresponding connections on terminals J
and/or K (see table 1 on page 11).
8.11 Auto-Droop Enable

When the engine speed is below approximately 1000 RPM (900-1100 RPM
depending on number of teeth on flywheel), Droop for that selected speed is
automatically enabled. This is ideal for idle speed situations where hunting
becomes noticeable.
Parameters for Engine Dynamics
8.12 GAIN
See point 9.1: Gain Points.
MENU 1
8.13 Stability
Increase STABILITY by pressing the + key until the engine becomes unstable, then
MENU 2 slowly reduce by tipping the –key until the engine returns to stable operation.
Continue to reduce for about 2 to 3 counts.
8.14 Derivative
In certain cases it can be necessary to adapt also the dead time compensation
MENU 6 (DERIVATIVE). If the engine oscillates fast, even if GAIN is low, reduce
DERIVATIVE by tipping the - key. If engine oscillates very slowly, increase
DERIVATIVE by tipping the + key .

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9. Setting of Maps
9.1 Gain points

MENU 1 At this point you are in the 8-point Gain Adjustment Map.
Each time the Menu button is pressed, the next Gain point will be accessed. Note:
MENU
An LED on the Bar Graph will illuminate indicating which Gain Point is active. Also,
note the Gain Value represented by the Bar Graph is not illuminated until you push
the [+] or [-] buttons.
To exit this mode you must press and hold the [RUN] button. This saves the
values you have just entered and exits the setup mode.
Chart 1 – Dynamic Gain Adjustment Specifics
100%
Gain
An example of individual Gain
settings for each of the 8 speed
ranges.
X X X
X Note: The speed ranges are fixed
X
X and only the Gain value is adjusted.
0% X
Gain X
0 800 1500 1800 Engine velocity [RPM]

500 1400 1650 1900
9.2 Max Setpoint Injection Mass (ME):

At this point you are in Injection Mass Limit setting.
The unit will be flashing out the limit in [mg/stroke] to the nearest whole value.
MENU MENU 3
Use the keypad or arrow keys to adjust value (High resolution here so you need to
press the + or – button 32 times before the next integer is flashed out.
10. Saving the SDG Settings

10.1 Saving the Settings
Press and hold the RUN key until the RUN/SETUP LED stops blinking. This causes the SDG to save
all settings into permanent memory. The SDG will now be in RUN mode verified by a steady
RUN/SETUP LED.
Without doing this all setting modifications will be lost when the SDG is turned off.
10.2 Dismissing of inapplicable Settings

Settings that are not satisfactory or wrong should not be saved into permanent memory.
When cycling power without saving the SDG will return to the previous settings.

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10.3 Factory Default Setting Recall

a) Enter Setup (see point 7.1)
b) Make sure no menus are selected (LEDs 0 thro 10 are off)
c) Enter 1-2-3-4 followed by the ENTER key.
d) SDG865 flashes out 4-3-2-1
e) Press and hold RUN key so save the recalled default settings.
11. Fault Handling

11.1 General
Faults can occur in the PSG (VP44 unit), MSG (SDG865), and externally in terms of wire connections.
The SDG865 continuously is monitoring for these faults and will take appropriate action once detected.
The Fault finding chart indicates what action is to be taken.
If a fault is detected before starting the engine, the fault LED will be steady on. If it is a critical fault then
the engine will not be allowed to start. If a fault is detect while the engine is running, the fault LED will
be flashing. If it is a critical fault then the engine will be commanded to shut down by commanding zero
fuel and the MAB line is pulled high. Please note if the external shut down is enabled, the Engine will be
allowed to run even when a critical fault is detected (with the exception of Overspeed). If a Critical Fault
is detected while in this mode, the SDG865 checks to see if it is an overspeed or if the Remote Shutdown
(E-stop) is triggered. If not then Fault 31 is logged in the Fault log. If the engine is damaged and Fault 31
is logged then the engine operator failed to shut down the engine.
Remote shutdown will be logged any time it is triggered (Fault 203). If the Remote shutdown is enabled
during starting, the engine will not start.
External alarm (terminal S) is triggered when any fault is detected.
11.2 Fault Log Read & Clear Options

Fault Log Read Out:
a) Enter Setup (see point 7).

MENU 8 b) Menu 0, Key 8.
c) 1-1-1-1 is flashed to begin the fault recall process.
d) All faults are flashed out (0-0-0-0 , 0-0-0-1, 0-0-02,… 0-2-0-5) if any have been
detected.
e) 2-2-2-2 is then flashed out indicating all the faults have been displayed.
f) If there are suppressed faults in the fault log they will be flashed out now.
g) 3-3-3-3 is flashed out to indicate the end of the fault retreaval procedure.
h) Exit by pressing RUN or cycling power.
Clearing the Fault Log:
a) Enter Setup
MENU MENU 8 b) Menu 1, Key 8.
c) SDG865 then flashes out 3-2-1-0 indicating fault log cleared.
d) Exit by pressing RUN or cycling power.

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11.3 Fault Code Table

Category Fault OCC ORD S Description Remarks
VP44 Status 0000 0 0 S Evaluation of solenoid valve current and When impossible to start
VP44 Status 0001 0 0 S fast decay voltage engine, change injection pump.
VP44 Status 0003 0 0 Start: a valid segment not recognized. Change injection pump.
Otherwise: currently static or dynamic
wrong.
VP44 Status 0004 0 0 No IAT pulse and crank speed > Change injection pump.
threshold or continuous pulse error.
VP44 Status 0005 0 0 Pump temperature > threshold. PSG is reducing power, check
fuel temperature and fuel
system.
VP44 Status 0006 0 0 Signal range check error. Sensor failure, default value for
temperature = 30°C.
VP44 Status 0007 0 0 Signal range check error. Sensing of supply voltage in
PSG fault.
VP44 Status 0008 0 0 S Persistent governor deviation. Possibly Air in fuel supply system.
oscillating timing piston. Continuous operation will
damage timing device.
VP44 Status 0011 0 0 Solenoid valve shut-off Cause for shut down.
VP44 Status 0012 0 0 Currently no pulse, Speed sensor on crank shaft
or more than 1 pulse fault.
VP44 Status 0013 0 0 S Currently no pulse, Speed sensor on crank shaft
or more than 1 pulse in valid angle fault.
range.
VP44 Status 0015 0 0 S Continuously no message of impaired Incorrect CAN message.
value range.
VP44 Self test 0100 0 0 Incorrect check sum. Wrong calculation of injection
amount.
VP44 Self test 0101 0 0 Hardware error. Wrong calculation of injection
amount.
VP44 Self test 0102 0 0 Incorrect analogue value Wrong calculation of injection
amount.
VP44 Self test 0103 0 0 S Pump map is not programmed or wrong Engine control unit may not
CAN interface (then bit 7 also set) start, change injection pump.
VP44 Self test 0104 0 0 S Hardware error. Engine control unit may not
start, change injection pump.
VP44 Self test 0105 0 0 a) Hardware error b)Solenoid valve Low voltage at start.
voltage measurement error (then bit 6
also set).
VP44 Self test 0107 0 0 S MSG and PSG are not able to Engine control unit may not
communicate due to wrong configu- start.
ration (bit 3 also set).
SDG faults 0200 0 0 S Internal failure Check wiring,
check configuration,
change SDG
SDG faults 0201 0 0 S No speed pickup signal MSP-6723: check wiring,
sensor front side: check
distance to ring gear,
change sensor.
SDG faults 0202 0 0 S No connections MSP-PSG (CAN H and L) Check wiring.
SDG faults 0203 0 0 Only stop modes: external shut off or Read fault memory
ignition off
SDG faults 0204 0 0 S Overspeed limit exceeded. Read fault memory,

check overspeed setting.
Suppressed fault 0012 Fault detected while in fault suppressed Shut down requested.
mode.
OCC: Occur, how many times the fault tripped.
ORD: Order, last order the fault tripped.
S: Engine shutdown

Version: Service-3
Status: actual
SDG-865-01-01
Engine SWITZERLAND

www.huegli-tech.com
11.4 Trouble Shooting
Trouble Shooting Check List
No Fault, LED signal Possible Cause Check Requirements, Remedy

1 Engine does not start
1.1 Supply failure? Low voltage Measure voltage across Verify voltage and polarity
Fuse terminals A(-) and B(+). (12 V or 24 V).
Battery and wiring Check battery voltage Too much voltage drop
while cranking. due to too small wiring or
Check wiring. weak battery.
Are any LEDs on? If not, replace SDG.
1.2 LED FAULT on? SDG in FAULT condition Overspeed limit was Recheck flywheel teeth
exceeded? and overspeed settings.
Cycle power OFF-ON.
Try to restart
1.3 LED RUN/SETUP SDG in SETUP mode Cycle power OFF-ON.
blinking? Try to restart.
1.4 LED GAIN on? Crank termination setting Crank termination setting Cycle power OFF-ON
too low. should be min. 50 RPM Try to restart.
above firing speed. Readjust setting if needed
1.5 both LED GAIN and No speed signal from Measure voltage on Should be min. 1.0 VRMS
DERIVATIVE off? magnetic speed sensor. terminals H and I during during cranking
cranking
1.6 Actuator failure. Check wiring. See wiring diagram.
Measure voltage on Compare with actuator
terminals C and D. specifications.
Measure actuator current. Do not disconnect actuator
while energized!
1.7 Bar Graph flashing SDG configuration corrupt. Check configuration. Reload software or
when power applied reconfigure the unit.
to SDG
1.8 Fuel supply failure Check fuel system.

Air in fuel system.
2 Engine not running at correct fixed speed
2.1 Configuration, Terminals J and K not Check wiring. If nothing is connected to J
Wiring properly configured. See table 1 and K the SDG is
configured for variable
speed.
2.2 Incorrect flywheel teeth Reconfigure
number.
2.3 Incorrect fixed speed Settings have to be made with the corresponding
settings. connections on J and K

Version: Service-3
Status: actual
SDG-865-01-01
Engine SWITZERLAND

www.huegli-tech.com
No Fault, LED signal Possible Cause Check Requirements, Remedy

3 Engine not running at correct variable speed
3.1 Pot-meter wiring Terminals E,F,G not Check wiring.
properly connected See table 1
3.2 Configuration Incorrect variable speed Reconfigure the variable
configuration speed pot-meter
4 Overspeed during starting, load transient or speed changes

4.1 LED FAULT on? Overspeed setting too low Check overspeed setting
Tuning not optimal Adjust GAIN, STABILITY.
eventually start ramp
Crank termination setting Check crank termination
too high setting
5 SETUP mode is not accessible

Refer to chapter 7, pt. 7.2: Accessing SETUP mode
6 Engine unstable
6.1 Slow periodic Battery voltage too low Check battery and wiring Replace battery
instability should be min. 20V with Use appropriate wiring.
24V-systems
6.2 Insufficient dead time Increase DERIVATIVE

compensation
6.3 Fast periodic GAIN to high Reduce GAIN
instability
6.4 Too much dead time Reduce DERIVATIVE
compensation.
6.5 Fault in fuel injection Eliminate fault in fuel
system injection system
6.6 Soft or worn coupling Check play in coupling Correct fault

Version: Service-3
Status: actual
SDG-865-01-01
Engine SWITZERLAND

www.huegli-tech.com
12. Dimensions
96 37
82.4 17.5
5
6.
Ø
A RUN /
GAIN
SETUP
B STABILITY FAULT
DERIVATIVE
C
D 10 1 2 3
9
E
8 4 5 6
7
127.4
F
141
6
G 5 7 8 9
4
H MENU
3 0 +
I 2 SETUP
1 _
J ENTER
0 RUN
M N O P Q R S T U V W X Y

SDG865 05-02-18 Operation Manual Service Version 3

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SDG865 05-02-18 Operation Manual Service Version 3

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Document: Operation Manual

Governing Approved: MR Date: 05-02-18 for Bosch VP44 Pump Tel.:+41-62-916 50 30

The SDG865 digital control unit (MSG)

The SDG provides all the necessary

1. Safety Instructions and Warnings

For damage, which is caused by neglecting instructions, misuse or wrong

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Governing Approved: MR Date: 05-02-18 for Bosch VP44 Pump Tel.:+41-62-916 50 30

1. Safety Instructions and Warnings ................................................................................1

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Governing Approved: MR Date: 05-02-18 for Bosch VP44 Pump Tel.:+41-62-916 50 30

W:\DOKUMENTATION 2\Geräte\G A C\Governors\S D G\Applications\MAN-VP44\Manual\SDG865-05-02-18-Operation Manual-Service Version-3.doc Page 3 of 18

Governing Approved: MR Date: 05-02-18 for Bosch VP44 Pump Tel.:+41-62-916 50 30

Input / Output Parameters:

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Governing Approved: MR Date: 05-02-18 for Bosch VP44 Pump Tel.:+41-62-916 50 30

4. Installation and Wiring

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Governing Approved: MR Date: 05-02-18 for Bosch VP44 Pump Tel.:+41-62-916 50 30

5. Inputs and Outputs

Speed Pickup H, I This input determines how the critical faults

Remote Shutdown Input Q CAN bus connections X, Y

Internal / External (Emergency Stop) enable R

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Governing Approved: MR Date: 05-02-18 for Bosch VP44 Pump Tel.:+41-62-916 50 30

GAIN LED Numeric keys

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Governing Approved: MR Date: 05-02-18 for Bosch VP44 Pump Tel.:+41-62-916 50 30

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Governing Approved: MR Date: 05-02-18 for Bosch VP44 Pump Tel.:+41-62-916 50 30

7.6 Bar Graph Display & Flash Codes

Bar Graph Display

Code Flash Mode

EXAMPLE 2 – Code Flash mode displaying the number 1500.

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Governing Approved: MR Date: 05-02-18 for Bosch VP44 Pump Tel.:+41-62-916 50 30

8. Setting of adjustable Parameters:

8.1 Flywheel Teeth

8.3 Crank Termination Setting

8.4 Speed Settings

8.5 Fixed Speed Operation

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Governing Approved: MR Date: 05-02-18 for Bosch VP44 Pump Tel.:+41-62-916 50 30

8.6 Variable Speed Operation

Make sure the potentiometer is attached as shown on the wiring diagram.

MENU 7 High speed

B (Battery +) to Jumper betw.

Speed [rpm] nstatic1 nstatic2 nstatic3 nvar

Droop [%] 0 0 0 0 yes no

Trim [rpm] 0 0 0 nvar,min

Trim [rpm] ±100 ±100 ±100 nvar

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Governing Approved: MR Date: 05-02-18 for Bosch VP44 Pump Tel.:+41-62-916 50 30

8.7 Starting Fuel Ramp Control

8.8 Starting Fuel Preset Point

8.9 Speed Ramping Control:

8.10 Droop Setting

8.11 Auto-Droop Enable

Parameters for Engine Dynamics

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Governing Approved: MR Date: 05-02-18 for Bosch VP44 Pump Tel.:+41-62-916 50 30

9.1 Gain points

Chart 1 – Dynamic Gain Adjustment Specifics

0 800 1500 1800 Engine velocity [RPM]