Heinzmann GmbH & Co.

KG
Engine & Turbine Management

Am Haselbach 1
D-79677 Schönau
Germany

Phone +49 7673 8208 - 0

Fax +49 7673 8208 - 188
E-mail info@heinzmann.de
www.heinzmann.com

V.A.T. No.: DE145551926

HEINZMANN
Engine & Turbine Management

Engine Simulator

Copyright 2011 by Heinzmann GmbH & Co. KG. All rights reserved.
This publication may not be reproduced by any means whatsoever or passed on to any third parties.

6170 Manual DG 11 010-e / 07-12

Version information

Version Description of changes Date Edited by

1.00 Created 11.04.11 R. Zeller

1.01 Section  2.6 Multiple gap wheel 13.05.11 R. Zeller
and  2.7 Misfire signal generation created
1.02 Section  2.8 Signal pattern generation created 05.07.11 R. Zeller
1.03 Section  2.2.4 Generating interference signals on the 04.08.11 R. Zeller
crankshaft and
 2.5 Engine speed signal development created
1.04 Section  2.2.5 Generating interference signals on the 09.09.11 R. Zeller
camshaft created
1.05 Frequency range added in section  2.1 General 22.12.11 R. Zeller

1.06 Section  2.2.4 Generating interference signals on the 12.04.12 R. Zeller

crankshaft revised
1.07 Section  2.9 Output signal generation added 27.07.12 R. Zeller
The appropriate manuals must be thoroughly studied before instal-
lation, initial start-up and maintenance.
All instructions pertaining to the system and safety must be followed in
full. Non-observance of the instructions may lead to injury to persons
and/or material damage.
HEINZMANN shall not be held liable for any damage caused through
non-observance of instructions.
Independent tests and inspections are of particular importance for all
applications in which a malfunction could result in injury to persons or
material damage.
All examples and data, as well as all other information in this manual
are there solely for the purpose of instruction and they may not be used
for special application without the operator running independent tests
and inspections beforehand.
HEINZMANN does not guarantee, neither expressly nor tacitly, that
the examples, data or other information in this manual is free from er-
ror, complies with industrial standards or fulfils the requirements of any
special application.

To avoid any injury to persons and damage to systems, the following

monitoring and protective systems must be provided:
 Overspeed protection independent of the rpm controller
HEINZMANN shall not be held liable for any damage caused through
missing or insufficiently rated overspeed protection.
 thermal overload protection
The following must also be provided for alternator systems:
 Overcurrent protection
 Protection against faulty synchronisation for excessively-large fre-
quency, voltage or phase difference
 Directional contactor
The reasons for overspeeding may be:
 Failure of positioning device, control unit or its auxiliary devices
 Linkage sluggishness and jamming

The following must be observed before an installation:

 Always disconnect the electrical mains supply before any interventions
to the system.
 Only use cable screening and mains supply connections that corre-
spond with the European Union EMC Directive
 Check the function of all installed protection and monitoring systems
Please observe the following for electronically controlled injection
(MVC):
 For common rail systems each injector line must be equipped with a
separate mechanical flow-rate limiter
 For unit pump (PLD) and pump-injector unit (PDE) systems, the
fuel enable is first made possible by the solenoid valve’s control
plunger motion. This means that in the event of the control plunger
sticking, the fuel supply to the injection valve is stopped.

As soon as the positioning device receives power, it can actuate the

controller output shaft automatically at any given time. The range of the
controller shaft or control linkage must therefore be secured against un-
authorised access.

HEINZMANN expressly rejects any implied guarantee pertaining to

any marketability or suitability for a special purpose, including in the
event that HEINZMANN was notified of such a special purpose or the
manual contains a reference to such a special purpose.

HEINZMANN shall not be held liable for any indirect and direct dam-
age nor for any incidental and consequential damage that results from
application of any of the examples, data or miscellaneous information
as given in this manual.

HEINZMANN shall not provide any guarantee for the design and planning
of the overall technical system. This is a matter of the operator its planners
and its specialist engineers. They are also responsible for checking whether
the performances of our devices match the intended purpose. The operator is
also responsible for a correct initial start-up of the overall system.
 Table of contents

Table of contents

Page

1 General ................................................................................................................................... 1

2 Standard simulator ............................................................................................................... 3

2.1 General............................................................................................................................. 3
2.2 Signal generation ............................................................................................................. 3
2.2.1 Configuration of the PickUp1 signals ...................................................................... 3
2.2.2 Configuration of the PickUp2 signal ....................................................................... 4
2.2.3 Configuration of the CamIndex signal ..................................................................... 4
2.2.3.1 Calculating the CamOffset ............................................................................... 5
2.2.4 Generating interference signals on the crankshaft ................................................... 5
2.2.5 Generating interference signals on the camshaft ..................................................... 5
2.3 Frequency simulation....................................................................................................... 6
2.4 Engine simulation ............................................................................................................ 6
2.5 Engine speed signal development .................................................................................... 7
2.5.1 Running DcDesk record files ................................................................................... 8
2.6 Multiple gap wheel .......................................................................................................... 8
2.7 Misfire signal generation ................................................................................................. 9
2.8 Signal pattern generation ............................................................................................... 10
2.9 Output signal generation ................................................................................................ 10

3 Pin assignment ..................................................................................................................... 13

 1 General

1 General
The engine simulator hardware is equipped with the following inputs and outputs:
 6 x frequency/PWM/digital outputs
 4 x frequency/PWM/digital inputs
 6 x analogue inputs
o 4 x 0..5 V
o 2 x 0..25 mA
 2 x analogue outputs
o 1 x 0..5 V
o 1 x 0..25 mA
 2 x CAN BUS
 1 x RS232
 48-pin extension plug

1
1 General

Fig. 1 Views of engine simulator

2
 2 Standard simulator

2 Standard simulator

2.1 General

The engine simulator can be used as a simulator for frequency or the engine, i.e. also in en-
gine-speed-controlled operation. It generates the signals of two crankshaft sensors and one
camshaft sensor via three frequency outputs. The configuration of these signals can be
freely selected.
The start condition can also be defined to ensure the engine is always started at the identi-
cal point. This is required if there are investigations into synchronisation.
The minimum frequency of the simulator is 5 Hz. The maximum frequency is set to 10000
Hz by default. Theoretically it is possible to have higher frequencies. This could be imple-
mented by request.

2.2 Signal generation

The signals from PickUp1 and PickUp2 are generated independently from each other, i.e.
they are in no way connected. This means that it is possible that the PickUp2 crankshaft
gap position may shift relatively towards that of PickUp1. Insofar as PickUp1 and PickUp2
have the same number of teeth, this shift is barely or not at all visible.
However, the camshaft signal is produced directly by PickUp1, i.e. this signal is exactly
synchronous with the PickUp1 signal. The signal width of the camshaft signal corresponds
to a PickUp1 tooth.
An internal tooth counter is used to generate the signal. This tooth counter runs from 1 to
double the number of teeth (i.e. for 60 teeth from 1 to 120). The PickUp1 gap position is
always generated at tooth no. 1 and the number of teeth set in the parameters. The PickUp2
gap position and the camshaft positions are entered relative to tooth number 1 by PickUp1.
The frequency creation always relates to PickUp1. The signals from PickUp2 and CamIn-
dex are generated from this frequency.

2.2.1 Configuration of the PickUp1 signals

1 TeethPickUp1 Number of teeth from PickUp1

2 NumberOfGapPickUp1 Number of gaps
3 ToothRatioPickUp1 Tooth ratio for PickUp1 signal
4 StartToothNo Tooth number at which the signal generation starts
upon engine start (see also 4110)
5 FrequencyRampPickUp1 Speed at which the frequency changes
4001 PickUp1GapHighOrLow Polarity of the signal in the gap (taken over only at
zero speed)
3
2 Standard simulator

4005 PU1FrequencyRampOn Activation of the frequency ramp

4110 ResetToothNoAtStop Reset tooth counter at engine stop. This will start
each engine start in the same position

2.2.2 Configuration of the PickUp2 signal

11 TeethPickUp2 Number of teeth from PickUp2

12 NumberOfGapPickUp2 Number of gaps
13 ToothRatioPickUp2 Tooth ratio for PickUp2 signal
14 TeethOffsetForGapPU2 Tooth offset of the PickUp2 gap relative to the
PickUp1 tooth counter (taken over only at zero
speed)
15 FrequencyRampPickUp2 Speed at which the frequency changes
4011 PickUp2GapHighOrLow Polarity of the signal in the gap (taken over only at
zero speed)
4015 PU1FrequencyRampOn Activation of the frequency ramp

2.2.3 Configuration of the CamIndex signal

21 CamSimulationMode Selection of the camshaft signal

0 = deactivated
1 = single pulse
2 = freely configurable
3 = trigger disc with 4+1 teeth
4 = trigger disc with 6+1 teeth
5 = trigger disc with 8+1 teeth
22 NoOfCamPositions Number of camshaft signals when the signal is freely
configured
24 CamOffset Tooth offset of the first camshaft signal relative to
the PickUp1 tooth counter
2250 CamPositions() Display of the number of teeth at which a camshaft
pulse is created (regarding the PickUp1 tooth coun-
ter)
4021 CamIndexHighOrLow Polarity of the signal (taken over only at zero speed)
6000 CamPositions() Number of teeth from the camshaft signals if config-
ured freely (regarding the PickUp1 tooth counter)

4
 2 Standard simulator

2.2.3.1 Calculating the CamOffset

In parameter 24, CamOffset, the tooth offset of the first camshaft signal relative to the
tooth counter of PickUp1 must be entered. This is the distance used by the MVC control
unit as a synchronising criterion. The CamOffset is calculated from the MVC control
unit parameters 3 SensorToGapPickUp1 and 5 SensorToCamIndex as follows:

For 3 SensorToGapPickUp1 < 5 SensorToCamIndex the following applies:

24 CamOffset = (720° + 3 SensorToGapPickUp1 - 5 SensorToCamIndex) /
360° * 1 TeethPickUp1
For 3 SensorToGapPickUp1 > 5 SensorToCamIndex the following applies:
24 CamOffset = (3 SensorToGapPickUp1 - 5 SensorToCamIndex) /
360° * 1 TeethPickUp1

2.2.4 Generating interference signals on the crankshaft

A signal failure of PickUp1 or PickUp2 can be simulated by setting the tooth ratio 3
ToothRatioPickUp1 or 13 ToothRatioPickUp2 to 0% or 100%.
To generate a synchronising fault, you can manually briefly change the number of gaps
2 NumberOfGapPickUp1 or 12 NumberOfGapPickUp2 to an incorrect value and imme-
diately back to the correct value.
However, this may cause synchronising faults to apply during one or several revolu-
tions. For this reason, there is also the option to generate a single synchronising fault. It
is possible to generate the two faults “gap detected, but tooth expected” and “tooth de-
tected, but gap expected”.
When activating parameter 4002 PU1SyncToothInGap or 4012 PU2SyncToothInGap
the gap is one time given as a tooth. An additional synchronising fault can be generated
by activating the parameter again.
Via parameter 4003 PU1SyncErrGapInTooth or 4013 PU2SyncErrGapInTooth on the
other hand the synchronising fault is generated by inserting one-time a gap instead of a
tooth at an arbitrary position. An additional synchronising fault can be generated by ac-
tivating the parameter again.

2.2.5 Generating interference signals on the camshaft

You can create a signal failure by setting parameter 21 CamSimulationMode to 0 (disabled).

A different configuration than that expected by the control unit may be entered in pa-
rameter 21 CamSimulationMode to generate an interference signal.

5
2 Standard simulator

Insofar as free mode has been selected (21 CamSimulationMode = 2), this can also be
performed by varying the number of pulses to be generated in parameter 22 NoOfCam-
Positions.
However, this may cause synchronising faults to apply during one or several revolu-
tions. For this reason, there is also the option to generate an individual synchronising
fault using parameter 4022 CamIndexSyncErrorOn. Upon activation, a pulse is sup-
pressed once. The pulse to be suppressed can be selected in parameter 25 CamSyncEr-
rorIndex. Enter the index of field 2250 CamPositions() here. It shows the tooth number
at which the camshaft pulse is created.
Activating parameter 4022 again will create another synchronising fault.

2.3 Frequency simulation

Switch 2812 SwSimEngineOrFreq must be set to 'Freq' for frequency simulation. Frequen-
cy simulation can be (de)activated using switch 2810 SwEngineOn.
The frequency specification can either be specified directly using DcDesk 2000 or using
two sensor values (usually potentiometers). Use 4100 FrequencyPotOrPC to select. If the
parameter is set to 'PC', the frequency specification is set using parameter 100 Frequen-
cySetpPC.
If they are specified using sensor values, both sensors, 2900 Setpoint1 and 2901 Setpoint2,
are used. They are selected using switch 2811 SwSetpoint2Or1.
The frequency generated from these sensors is shown in parameter 2101 FrequencySetp1
and/or 2102 FrequencySetp2.
Parameter 5 FrequencyRampPickUp1 and/or 15 FrequencyRampPickUp2 specify the
change speed of the frequency specification.

2.4 Engine simulation

Switch 2812 SwSimEngineOrFreq must be set to 'Engine' to trigger an engine simulation.

The engine simulation can be (de)activated using switch 2810 SwEngineOn.
Information on the current torque is required for engine simulation. It is connected in 2902
TorqueInput.
The target torque specification can be specified either directly using DcDesk 2000 or using
two sensor values (usually potentiometers). It is selected using 4150 TorquePotOrPC. If the
parameter is set to 'PC', the frequency specification is set using parameter 150 Tor-
queSetpPC.
If they are specified using sensor values, both sensors, 2900 Setpoint1 and 2901 Setpoint2,
are used. They are selected using switch 2811 SwSetpoint2Or1.

6
 2 Standard simulator

The torque generated from these sensors is shown in parameters 2201 TorqueSetp1 and/or
2202 TorqueSetp2.
The target torque value the simulator operates with is shown in 2051 EngineTorqueSetp.
Parameter 5 FrequencyRampPickUp1 and/or 15 FrequencyRampPickUp2 specify the
change speed of the frequency specification.
The engine's moment of inertia is specified in parameter 200 MomentOfInertia. Smaller
values result in a faster engine.
Parameters 6100..6250 are used to specify characteristic maps for the minimum and maxi-
mum engine torque. No additional torque is generated above the maximum torque, i.e. if
more torque is requested, the engine is overloaded and the engine speed drops.
The percentage value of the current engine torque is defined by 2902 TorqueInput, with re-
gard to these characteristic maps. This torque is shown in 2050 EngineTorque.
The starter speed is specified in parameter 250 StarterSpeed. This starter speed is generated
if the engine is off and switch 2810 SwEngineOn goes to 'On'. Insofar as the target torque
is smaller than that required for engine start (from characteristic curve), the engine starts.
The starter speed is overlaid by a sine-shaped oscillation to simulate the starter action.

2.5 Engine speed signal development

Instead of simulating an engine, the engine speed signal can also be created using a repro-
ducible specification in which you can define parameters.
For this purpose, switch 2812 SwSimEngineOrFreq must be set to 'Engine'. In function
4101 SpeedCurvOrEngineSim you must also select 'SpeedCurve'.
The engine speed signal can be (de)activated using switch 2810 SwEngineOn.
The engine speed signal must be entered in the following parameters:
7000 SpeedSim:t() Time for engine speed signal
7300 SpeedSim:n() Associated engine speed values
As soon as switch input 2810 SwEngineOn is activated, engine speed signal generation be-
gins as per the procedure defined in the parameters. Once the signal has run completely, the
last engine speed signal value is maintained.
Deactivation followed by a reactivation of 2810 SwEngineOn generates the same signal
sequence.

The frequency ramp is valid also when generating the signal. Deactivate the
frequency ramp if the exact procedure as defined in the parameters is to be
generated.

7
2 Standard simulator

2.5.1 Running DcDesk record files

This function therefore also enables DcDesk record files to be played. For this purpose,
first save the parameters of both characteristic curves as hzm files and then open this
hzm file and the desired rec file in CodeWright. There you can mark the two columns
for the time axis and the engine speed value one after the other and transfer them to the
hzm file.
It might be advisable to perform this using Excel to compensate for an offset of the time
axis and to round off the engine speed values.

2.6 Multiple gap wheel

Some special applications require a multiple gap wheel. In the process, there are several
gaps on the measuring wheel and the number of teeth between the individual gaps varies.
This enables very fast synchronising as only the number of teeth between the gaps must be
counted.
The engine simulator supports the generation of such signals on PickUp1 and PickUp2.
Both PickUps create the signal of the same gear wheel (if required, different wheels may
also be implemented).

In a multiple gap wheel, displacement of the PickUp2 signal using parameter

14 TeethOffsetForGapPU2 upon engine start generates an incorrect PU2 sig-
nal and the offset is also incorrect – for this reason, leave parameter 14 at 0
(item for the to-do list).

In the process, take into account the following parameters:

6 NumberOfMultiGaps Number of gaps on the gear wheel
2020 MultiGapIndexPickUp1 Displays the gap index PickUp1
2021 MultiGapIndexPickUp2 Displays the gap index PickUp2
4006 PU1MultiGapWheelOn Activates the multiple gap signal PickUp1
4016 PU2MultiGapWheelOn Activates the multiple gap signal PickUp2
6050 MultiGapPositions() Setting parameters of the gap positions
Enter the tooth numbers of the gap positions in field 6050 MultiGapPositions(), i.e. a gap is
generated instead of a tooth for each figure. Please ensure that the numbers are entered in
ascending order. The last gap position must also exactly correspond to the number of teeth
from parameter 1.
For example: MAN special gear wheel with 240 teeth and 8 gaps
1 TeethPickUp1 = 240

8
 2 Standard simulator

5 NumberOfMultiGaps =8
4003 PU1MultiGapWheelOn =1
6050 MultiGapPositions(0) = 21
6051 MultiGapPositions(1) = 63
6052 MultiGapPositions(2) = 91
6053 MultiGapPositions(3) = 117
6054 MultiGapPositions(4) = 149
6055 MultiGapPositions(5) = 179
6056 MultiGapPositions(6) = 215
6057 MultiGapPositions(7) = 240

2.7 Misfire signal generation

The engine simulator can create a misfire signal. However, this is not within the scope of
the standard simulator software. This process requires variant 2.
Misfire signal generation stores a table with engine speed values in the control unit. The
values can be run on request. This process enables the creation of a reproducible misfire
engine speed signal.
4200 MisfireSignalOn Activating the misfire signal generation
Setting this parameter to 1 will generate the signal. The table stored in the control unit is
run once, then the signal is generated "normally" again. Generating the signal can be inter-
rupted by setting the parameter to 0.
This may also be performed using switch function 2814 SwMisfireSignalOn. In the pro-
cess, switch flank 0  1 is evaluated and simulation activated if it is not yet running and
would otherwise deactivate.
To ensure that the signal analysis of the connected engine speed sensor operates correctly,
it is required to set the correct parameters for the number of teeth and the simulation fre-
quency in the engine simulator and the speed governor.
The engine simulator currently contains the misfire signal of a Guascor 16-cylinder gas-
powered engine. In this engine, 12 different cylinders were briefly connected so that the
corresponding cylinder did not fire. The engine speed sequence was recorded and can be
reproduced using the engine simulator.
The engine had 165 teeth and was operated at 1500 rpm. For the engine simulator this
means that a frequency of 4125 Hz must be set.
As a rule, the recorded signal may also be modulated to other signals. However, this no
longer corresponds to a real signal sequence.

9
2 Standard simulator

With the above signal, the recorded signal has a duration of 144 seconds and requires
around 600 kB of memory in the control unit.

2.8 Signal pattern generation

The outputs may also be used to output a signal pattern. For this purpose, the standard sim-
ulator has three outputs; others may have up to six.
The signal has a resolution of 1 ms (if required, a more precise output signal generation
may be implemented) and a maximum duration of 65.535 s.
The signal pattern of all outputs is started at the same time, i.e. the signal pattern of all out-
puts is synchronous. The start of the signal pattern can either be performed using function
4300 SignalPatternOn or switch function 2815 SwSignalPatternOn. The signal pattern is
generated until both requests have been reset or the entire signal generation time has ex-
pired. Restarting the signal pattern initially requires resetting the signal.
The parameters of the signal pattern are set via the following parameters
16000 Pattern1:Time Time frame for signal pattern
16100 Pattern1:Level Output level for signal pattern
and the following parameters for additional signals. Setting the parameter to 0 ms in an el-
ement greater than Index 0 in Pattern1:Time() indicates the end of signal generation. The
signal level of the last element is maintained until the signal generation time has expired.
The signal patterns created are shown on parameter
2301 Pattern1 the current output level for signal patterns
and the following. These output levels can be assigned to the desired output via the normal
parameter settings of the digital outputs (parameter 8800ff). In the process, the outputs
must be set to binary outputs (parameter 4800ff).

2.9 Output signal generation

There is also the possibility to generate an arbitrary signal which may be used for output
via an analogue or PWM output.
The parameters of the signal generation are set via the following parameters
1700 SignalGenSetpoint setpoint of the signal
1701 SignalGenAmplitude amplitude of the signal
1702 SignalGenFrequency frequency of the signal
3700 SigGenOutput generated signal
5701 SignalGenMode mode of the signal:

10
 2 Standard simulator

0 = straight
1 = square wave
2 = triangular wave
3 = sine wave
The generated signal 3700 SigGenOutput may be assigned to any analogue or PWM out-
put. If using an analogue output, please note on high frequencies the output signal may be
damped by the hardware filter circuit on the board.

11
 3 Pin assignment

3 Pin assignment
Pin Name Meaning Use in
standard simulator
1 PS Power supply
2 GND Earth
3 VCC1 Supply of analogue input 1 (5V)
4 AI1 Analogue input 1 (0..5V) Target value 1
5 GND Earth of analogue input 1
6 VCC1 Supply of analogue input 2 (5V)
7 AI2 Analogue input 2 (0..5V) Target value 2
8 GND Earth of analogue input 2
9 VCC2 Supply of analogue input 3 (5V)
10 AI3 Analogue input 3 (0..5V) Filling signal (analogue)
11 GND Earth of analogue input 3
12 VCC2 Supply of analogue input 4 (5V)
13 AI4 Analogue input 4 (0..5V)
14 GND Earth of analogue input 4
15 AI5 Analogue input 5 (0..25mA)
16 GND Earth of analogue input 5
17 AI6 Analogue input 6 (0..25mA)
18 GND Earth of analogue input 6
19 AO1 Analogue output 1 (0..25 mA)
20 GND Earth of analogue output 1
21 AO2 Analogue output 2 (0..5V)
22 GND Earth of analogue output 2
23 DI1 Digital/PWM input 1 Signal on/off
24 GND Earth of digital/PWM input 1
25 DI2 Digital/PWM input 2 Target value 2 or 1
26 GND Earth of digital/PWM input 2
27 DI3 Digital/PWM input 3 Select frequency or
engine simulation
28 GND Earth of digital/PWM input 3
29 DI4 Digital/PWM input 4 Filling signal (PWM)
30 GND Earth of digital/PWM input 4
31 VDD Supply 5V
32 GND Earth
33 DO1 Frequency/PWM output 1 PickUp1 signal
34 GND Earth of frequency/PWM output 1
35 DO2 Frequency/PWM output 2 PickUp2 signal

13
3 Pin assignment

36 GND Earth of frequency/PWM output 2

37 DO3 Frequency/PWM output 3 CamIndex signal
38 GND Earth of frequency/PWM output 3
39 DO4 Frequency/PWM output 4
40 GND Earth of frequency/PWM output 4
41 DO5 Frequency/PWM output 5
42 GND Earth of frequency/PWM output 5
43 DO6 Frequency/PWM output 6
44 GND Earth of frequency/PWM output 6
45 CAN1-H CAN bus 1 high
46 CAN1-L CAN bus 1 low
47 CAN2-H CAN bus 2 high
48 CAN2-L CAN bus 2 low

14