Fritz Heinzmann

GmbH & Co.

Drehzahlregler

Am Haselbach 1
D-79677 Schönau (Schwarzwald)
Germany

Telefon (0 76 73) 82 08-0

Telefax (0 76 73) 82 08-188
e-mail info@heinzmann.de

USt-IdNo.: DE145551926

HEINZMANN®
Digital Speed Governors

Digital Basic System

PANDAROS V

DG L20.6 - 01 up to - 05

DG L40.6 - 01 up to - 05

Copyright 2001 by Heinzmann GmbH & Co. All rights reserved. This document may not be reproduced or handed on to third parties.

Manual DG 01 004-e / 10-02

HEINZMANN®

Read this entire manual and all other publications appertaining to the
work to be performed before installing, operating or servicing your
equipment.
Practice all plant and safety instructions and precautions.
Warning

Failure to follow instructions may result in personal injury and/or

damage to property.
HEINZMANN will refuse all liability for injury or damage which
Danger results from not following instructions

Please note before commissioning the installation:

Before starting to install any equipment, the installation must have been
switched dead!
Danger!
High
Voltage Be sure to use cable shieldings and power supply connections meeting
the requirements of the European Directive concerning EMI.

Check the functionality of the existing protection and monitoring

Danger systems.

To prevent damages to the equipment and personal injuries, it is

imperative that the following monitoring and protection systems
have been installed:
Overspeed protection acting independently of the speed governor
Danger
Overtemperature protection
HEINZMANN will refuse all liability for damage which results from
missing or insufficiently working overspeed protection.
Generator installation will in addition require:
Overcurrent protection
Protection against faulty synchronization due to excessive frequency,
voltage or phase differences
Reverse power protection

Overspeeding can be caused by:

Failure of the voltage supply
Failure of the control unit or of any accessory device
Failure of the actuator
Sluggish and blocking linkage
 HEINZMANN®

Electronically controlled injection (MVC) will in addition require

to observe the following:
With Common Rail systems a separate mechanical flow limiter must
be provided for each injector pipe.
Warning With Pump-Pipe-Nozzle (PPN) and Pump Nozzle (PNE) systems fuel
release may be enabled only by the movement of control piston of the
solenoid valve. This is to inhibit fuel from being delivered to the
injection nozzle in case of seizure of the control piston.

The examples, data and any other information in this manual are
intended exclusively as instruction aids and should not be used in any
particular application without independent testing and verification by
Warning the person making the application.

Independent testing and verification are especially important in any

application in which malfunction might result in personal injury or
damage to property.
Danger

HEINZMANN make no warranties, express or implied, that the

examples, data, or other information in this volume are free of error,
that they are consistent with industry standards, or that they will meet
the requirements for any particular application.

HEINZMANN expressly disclaim the implied warranties of

merchantability and of fitness for any particular purpose, even if
HEINZMANN have been advised of a particular purpose and even if a
particular purpose is indicated in the manual.

HEINZMANN also disclaim all liability for direct, indirect, incidental

or consequential damages that result from any use of the examples,
data, or other information contained in this manual.

HEINZMANN make no warranties for the conception and engineering

of the technical installation as a whole. This is the responsibility of the
user and of his planning staff and specialists. It is also their
responsibility to verify whether the performance features of our devices
will meet the intended purposes. The user is also responsible for correct
commissioning of the total installation.
HEINZMANN®

Contents

Contents

Page

1 Safety Instructions and Related Symbols ........................................................................... 1

1.1 Basic Safety Measures for Normal Operation................................................................. 2
1.2 Basic Safety Measures for Servicing and Maintenance .................................................. 2
1.3 Before Putting an Installation into Service after Maintenance and Repair Works ......... 3

2 General ................................................................................................................................... 4

3 Functions ................................................................................................................................ 5
3.1 General Functions............................................................................................................ 5
3.2 Variation specific additional Functions........................................................................... 6
3.2.1 Variation DC 6-01 (Standard Generator) .................................................................. 6
3.2.2 Variation DC 6-02 (Standard General) ..................................................................... 6
3.2.3 Variation DC 6-03 (Extended Generator 1) .............................................................. 7
3.2.4 Variation DC 6-04 (Extended Generator 2) .............................................................. 7
3.2.5 Variation DC 6-05 (Extended General, especially vehicle)...................................... 7

4 Further Informations............................................................................................................ 8

5 Block Diagram ....................................................................................................................... 9

6 Sensors.................................................................................................................................. 10
6.1 Overview ....................................................................................................................... 10
6.2 Magnetic Pickup IA ...................................................................................................... 11
6.2.1 Technical Datas ....................................................................................................... 11
6.2.2 Installation............................................................................................................... 11
6.2.3 Tooth profile............................................................................................................ 12
6.2.4 Clearance of Magnetic Pickup ................................................................................ 12
6.2.5 Mounting Measurements......................................................................................... 13
6.3 Cooling Medium Temperature Sensor TS 01 - 28 - PT 1000 ....................................... 13
6.4 Pressure Sensors ............................................................................................................ 14
6.4.1 Oil Pressure Sensor ................................................................................................. 14
6.4.2 Boost Pressure Sensors ........................................................................................... 15
6.4.2.1 Boost Pressure Sensor with Plug...................................................................... 16
6.4.2.2 Boost Pressure Sensor with Housing and Terminal Strip ................................ 16

7 Setpoint Adjusters ............................................................................................................... 18

7.1 Setpoint Potentiometer SW 01 - 1 - b (1 turn)............................................................... 18

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Contents

7.2 Setpoint Potentiometer SW 02 - 10 - b (10- turn) ......................................................... 18

7.3 Setpoint Value Adjustment by Current Signal .............................................................. 19
7.4 Digital Presetting of Setpoint Values ............................................................................ 19
7.5 Setpoint Value Adjustment by Pedal............................................................................. 19
7.6 Pneumatic Setpoint Adjuster ......................................................................................... 19

8 Control Unit DC 6 – 01..05 ................................................................................................. 20

8.1 Specification .................................................................................................................. 20
8.1.1 General .................................................................................................................... 20
8.1.2 Inputs and Outputs .................................................................................................. 20
8.2 Measurements................................................................................................................ 22
8.3 Mounting ....................................................................................................................... 24

9 Actuators .............................................................................................................................. 25
9.1 Design and Mode of Operation ..................................................................................... 25
9.2 Installation ..................................................................................................................... 26
9.3 Specification .................................................................................................................. 27
9.4 Measurements................................................................................................................ 28

10 Electrical Connection........................................................................................................ 30
10.1 Connection for variation DG 6-01 (Standard Generator)............................................ 30
10.2 Connection for variation DG 6-02 (Standard General) ............................................... 31
10.3 Connection for variation DG 6-03 (Extended Generator 1)........................................ 32
10.4 Connection for variation DG 6-04 (Extended Generator 2)........................................ 33
10.5 Connection for variation DG 6-05 (Extended General) .............................................. 34
10.6 Harness ........................................................................................................................ 34

11 Parametrization Possibilities............................................................................................ 37
11.1 Parametrization at the Factory..................................................................................... 37
11.2 Parametrization with the Hand Held Programmer 3 ................................................... 37
11.3 Parametrization with the Keybord on the Control Unit .............................................. 37
11.4 Parametrization with the PC........................................................................................ 37
11.5 Parametrization with User Masks................................................................................ 38
11.6 Transferring Data Sets................................................................................................. 38
11.7 Assembly Line End Programming .............................................................................. 38

12 Starting the Engine - Brief Instructions.......................................................................... 39

13 Order Information ............................................................................................................ 40

14 Order Specifications for Manuals.................................................................................... 41

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1 Safety Instructions and Related Symbols

1 Safety Instructions and Related Symbols

This publication offers wherever necessary practical safety instructions to indicate inevitable
residual risks when operating the engine. These residual risks imply dangers to
persons
product and engine
environment.
The symbols used in this publication are in the first place intended to direct your attention to
the safety instructions!

This symbol is to indicate that there may exist dangers to the engine, to the
material and to the environment.
Warning

This symbol is to indicate that there may exist dangers to persons. (Danger to life,
personal injury).
Danger

This symbol is to indicate that there exist particular danger due to electrical high
tension. (Mortal danger).
Danger!
High
Voltage

This symbol does not refer to any safety instructions but offers important
notes for better understanding the functions that are being discussed. They
should by all means be observed and practiced. The respective text is
Note printed in italics.

The primary issue of these safety instructions is to prevent personal injuries!

Whenever some safety instruction is preceded by a warning triangle labelled “Danger” this is
to indicate that it is not possible to definitely exclude the presence of danger to persons,
engine, material and/or environment.

If, however, some safety instruction is preceded by the warning triangle labelled “Caution”
this will indicate that danger of life or personal injury is not involved.

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1 Safety Instructions and Related Symbols

The symbols used in the text do not supersede the safety instructions. So please do not
skip the respective texts but read them thoroughly!

In this publication the Table of Contents is preceded by diverse instructions that

among other things serve to ensure safety of operation. It is absolutely imperative
that these hints be read and understood before commissioning or servicing the
installation.

1.1 Basic Safety Measures for Normal Operation

• The installation may be operated only by authorized persons who have been duly
trained and who are fully acquainted with the operating instructions so that they are
capable of working in accordance with them.
• Before turning the installation on please verify and make sure that
- only authorized persons are present within the working range of the engine;
- nobody will be in danger of suffering injuries by starting the engine.
• Before starting the engine always check the installation for visible damages and make
sure it is not put into operation unless it is in perfect condition. On detecting any faults
please inform your superior immediately!
• Before starting the engine remove any unnecessary material and/or objects from the
working range of the installation/engine.
• Before starting the engine check and make sure that all safety devices are working
properly!

1.2 Basic Safety Measures for Servicing and Maintenance

• Before performing any maintenance or repair work make sure the working area of the
engine has been closed to unauthorized persons. Put on a sign warning that
maintenance or repair work is being done.
• Before performing any maintenance or repair work switch off the master switch of the
power supply and secure it by a padlock! The key must be kept by the person
performing the maintenance and repair works.
• Before performing any maintenance and repair work make sure that all parts of engine
to be touched have cooled down to ambient temperature and are dead!
• Refasten loose connections!

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1 Safety Instructions and Related Symbols

• Replace at once any damaged lines and/or cables!

• Keep the cabinet always closed. Access should be permitted only to authorized
persons having a key or tools.
• Never use a water hose to clean cabinets or other casings of electric equipment!

1.3 Before Putting an Installation into Service after Maintenance and Repair
Works

• Check on all slackened screw connections to have been tightened again!

• Make sure the control linkage has been reattached and all cables have been
reconnected.
• Make sure all safety devices of the installation are in perfect order and are working
properly!

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2 General

2 General

The HEINZMANN Digital Governors of the PANDAROS series have been designed as
speed governors for diesel and gas engines with low and medium power. In addition to their
primary purpose of controlling speed, these governors are capable of performing some other
tasks and functions.

The control system consists of the control unit, the actuator, the setpoint adjusters, the
sensors, and the connection cables.

The control unit includes the control electronics. At the core of the control unit is a very fast
and powerful 16 bit microprocessor. The actual controller programme based on which the
processor operates is permanently stored in a FLASH-EPROM.

The current engine speed is sensed by a magnetic pickup on the flywheel or a measuring
wheel.

One temperature sensor can measure the engine temperature and can cause changings of
governor parameters or alarm messages.

The speed setpoint, additional sensor inputs and the inputs for the analogue accessory are
depending on variations. There are 5 standard variations available. More variations are
possible on customer request.

All variations are available optional with integrated hand programmer.

With the serial interface ISO 9141 resp. RS 232 is communication to other devices possible.

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3 Functions

3 Functions

The HEINZMANN electronic governors of PANDAROS series are speed governors that
offer a small range of functions. Even so, in addition to speed regulation, there are depending
on the variation the following functions available:

3.1 General Functions

a) Start Quantity Adjustment

For setting start quantity, minimum start quantity or maximum start quantity may
alternatively be selected. If necessary either can be configured in dependence of
temperature. Furthermore, variable start quantity can be provided, by which start
quantity is automatically increased during start-up.

b) Speed Ramps
For applications where speed is not supposed to respond to changes of setpoint values
as fast as possible, a speed ramp is available. According to requirements, it may be
parametrized separately for increasing or decreasing speed. In addition, a separate speed
ramp is provided for start-up which will make the engine ramp slowly to operating
speed after starting.

c) All speed governing with adjustable droop

Some applications require speed governing with droop, e,g, generator parallel operation
without HEINZMANN load measuring unit. The droop can be adjusted as desired.
With droop adjusted to 0, the governor operates in isochronuous mode.

d) Setting the speed range

The minimum and maximum speed adjustable by the (external) setpoint, can be
parametrised.

e) Engine stop
When the switch input for engine shutdown is activated, the governor will cause the
actuator to fully pull to stop direction until the engine has stopped.

f) Overspeed protection
An overspeed point can be parametrised. If this point is overcome, the governor will
issue an alarm and the actuator will fully pull to stop direction.

g) Correction of PID Parameters

To optimize the dynamics for every operating point, the PID parameters may be
corrected in dependence of speed, temperature and load by means of freely
programmable stability maps.

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3 Functions

h) Speed Dependent Quantity Limitation

It is possible to programme quantity limitation curves in dependence of speed so that for
all speeds there can be torque reduction as is admissible for the engine or desired by the
user.

i) Temperature Dependent Idling Speed and Quantity Limitation

At low temperatures, the engine can be run at some higher idling speed. With the engine
warming up, idling speed is reduced to its normal value. It is possible to programme
quantity limitation curves in dependence of temperature so that for every temperature
there will be torque reduction available as is admissible for the engine or desired by the
user.

j) Operating Hour Meter

The operating hours when the engine is turning (speed is detected) will be added.

k) Failure Diagnosis and Display

If a sensor or the actuator is at fault, an alarm is issued and there will be a change-over
to emergency operation if so provided or an engine shutdown. Internal errors get
detected also and they will be stored as all other failures. All failures can be read out
with an external handprogrammer, the optional internal handprogrammer, or, if a
communication program with communication cable is existing with a PC or laptop
computer.

l) Communication
Two serial interface ports are available: ISO 9141 and RS-232.

3.2 Variation specific additional Functions

3.2.1 Variation DC 6-01 (Standard Generator)

(refer to connection diagram page 26)

The setpoint is realized with two push buttons: increase speed and decrease speed.

3.2.2 Variation DC 6-02 (Standard General)

(refer to connection diagram page 27)

The setpoint is given by an analogue setpoint source (voltage source 0..5 V, current
4..20 mA or potentiometer 5 kΩ) and one switch input for fixed speed.

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3 Functions

3.2.3 Variation DC 6-03 (Extended Generator 1)

(refer to connection diagram page 28)

The speed setpoint is realized with two switch inputs to increase speed and decrease
speed each.

The HEINZMANN load measuring unit is connected to an additional analogue input

for load governing in parallel operation.

An additional switch input it to select if the switch inputs for synchronization or the
analogue input from the load measuring unit is active.

3.2.4 Variation DC 6-04 (Extended Generator 2)

(refer to connection diagram page 29)

The setpoint is given by an analogue setpoint source (voltage source 0..5 V, current
4..20 mA or potentiometer 5kΩ).

Two additional analogue inputs are used for connecting the HEINZMANN load
measuring unit for load governing in parallel mode and for connecting the
HEINZMANN synchronizer.

A switch input is to select if the inputs of the HEINZMANN units or if the analogue
setpoint source is active.

3.2.5 Variation DC 6-05 (Extended General, especially vehicle)

(refer to connection diagram page 30)

The setpoint is given by an analogue setpoint source (voltage source 0..5 V, current
4..20 mA or potentiometer 5kΩ) and a switch input for fixed speed.

For turbocharged engines, fuelling can be reduced to achieve smokeless operation

whenever there is no boost pressure (e.g., during start-up or on load changes). The
respective limit curves can be programmed accordingly.

For the purpose of oil pressure monitoring, speed/pressure dependent limit curves can
be provided. If oil pressure is low, an alarm is issued; if oil pressure continues to drop,
the engine is shut down.

The governor may also be adjusted as an idle/max speed governor.

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4 Further Informations

4 Further Informations

This publication describes in detail the technical data and connections of the control
electronics, of the sensors, of the setpoint adjusters and of the actuators.

The functions of the different adjustment parameters and characteristics are described in
detail in the manual
Basic Information PANDAROS 6-01, Manual-No. DG 02 006-e.
Basic Information PANDAROS 6-02, Manual-No. DG 02 007-e.
Basic Information PANDAROS 6-03, Manual-No. DG 02 008-e.
Basic Information PANDAROS 6-04, Manual-No. DG 02 009-e.
Basic Information PANDAROS 6-05, Manual-No. DG 02 010-e.
The mode of operation of the communication programme DcDesk 2000 is described in detail
in the manual
Operation Instructions of Communication Program DcDesk 2000,
Manual-No. DG 00 003-e.

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5 Block Diagram

5 Block Diagram

WINDOW

FUNCTION
ESCAPE

ENTER

LCD-Display

Integrated Hand Programmer

Speed Sensor
Micro Controler

Switch Inputs Pressure Sensors

Analogue Setpoint Adjuster Temperature Sensor

Analogue Actuator Position

Synchronizer Sensing

Analogue
Load Measuring Unit
Actuator
M Drive

Failure Lamp

EEP-
ROM
Interface RS 232
ISO9141
5V
DC
24 V - Power Supply -
Watch- Watch- Watch-
DC dog 1 dog 2 dog 3

DC 6 Board

Fig. 1: Block Diagram

According to the different types, there are not all functions and inputs available!

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6 Sensors

6 Sensors

6.1 Overview

Sensor Speed Coolant Oil Pressure Boost Pressure

Temperature
HZM Designation IA .. TS 01-28-PT1000 DSO 01-6 DSL/G 0..-2
DSO 01-10 DSL/G 0..-5
DSL/G 0..-10
Connection SV 6-IA-2K SV 6-IA-2K DIN 43650 A DIN 43650 A
2 pole 2 pole 2 Line System 2 Line System
Measuring Procedure inductive, active PT1000, passive active active
Measuring Range 50...9.000 Hz -50...+150°C 0...6 bar 0...2 bar
0...10 bar 0...5 bar
0...10 bar
Supply Voltage passive 10...34 V DC 12...36 V DC
Range
Output Signal Range 0...10 V AC ca. 700...1500 Ohm 4...20 mA 4...20 mA
Operating -55...+120°C -50...+150°C -25...+125°C -40...+100°C
Temperature Range

In order to ensure maximum flexibility with regard to the sensors, the minimum/ maximum
current values and the measuring ranges of the pressure and temperature sensors have been
provided programmable.

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6 Sensors

6.2 Magnetic Pickup IA ...

6.2.1 Technical Datas

Operating principle inductive sensor

Distance from sensing gear 0.5 .. 0.8 mm
Output 0 V .. 10 V AC
Signal form Sine (depending on tooth shape)
Resistance approx.. 52 Ohm
Temperature range -55°C up to +125°C
Protection grade IP 55
Vibration < 10g, 10 .. 100 Hz
Shock < 50g, 11 ms half sine wave
Corresponding plug SV 6 - IA - 2K (EDV- No.: 010-02-170-00)

6.2.2 Installation

The installation of the pickup has to be arranged in such a way as to obtain a frequency
as high as possible. Normally, the HEINZMANN governors of the series Pandaros are
designed for a maximum frequency of 9000 Hz. Frequency (by Hz) is calculated
according to the formula

n(1 / min) * z
f (Hz) =
60

z = number of teeth on the pickup wheel

Example:

n = 1.500
z = 160

f = = 4.000 Hz

NB: It should be taken care that the speed can be measured by the pulse pickup
without any bias. For best results therefore, the speed pickup should take the
engine speed from the crankshaft. A suitable position for this is, e.g., the starter
gear (but not the injection pump wheel).

The pickup gear must consist of magnetic material (e.g., steel, cast iron).

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6 Sensors

6.2.3 Tooth profile

Any tooth profile is admissible. The top width of the tooth should be 2.5 mm minimum,
the gap and the depth of the gap at least 4 mm. For index plates the same dimensions are
valid.

Due to tolerances, a radial arrangement of the magnetic pickup is preferable..

6.2.4 Clearance of Magnetic Pickup

The distance between the magnetic pulse pickup and the tooth top should range from
0.5 and 0.8 mm. (It is possible to screw in the magnetic pickup till it touches the tooth
and then unscrew it for about half a turn.)

Fig. 2: Clerance of Pickup

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6 Sensors

6.2.5 Mounting Measurements

19

L 35

Fig. 3: Measurements of Pickup

Measures L
G Remarks
Type (mm)
01 - 38 38 M 16 x 1,5
02 - 76 76 M 16 x 1,5 appropriate
03 - 102 102 M 16 x 1,5 plug
11 - 38 38 5/8"-18UNF-2A SV6-IA-2K
12 - 76 76 5/8"-18UNF-2A
13 - 102 102 5/8"-18UNF-2A

Ordering specification, e.g. IA 02-76

6.3 Cooling Medium Temperature Sensor TS 01 - 28 - PT 1000

(EDV- No.: 600 00 053 00)

Measuring range -50°C up to +150°C

Precision ±1.5°C
Resistance at 25 °C (R25) 1000 Ohm ±0.5 %
Maximum operating voltage 5V
Maximum operating current 3 mA
Recommended operating current approx 1mA
Time constant in fluids approx. 13 seconds
Admissible temperature range
connector socket -40°C up to +105°C
Protection grade IP 65
Vibration < 20 g, 10 - 300 Hz
Shock < 50 g, 11 ms half-sine wave
Tightening torque 50 Nm ±15 %
Connector SV 6 - IA - 2K (EDV- No.: 010 02 170 00)

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6 Sensors

seal ring DIN 7603-14x18 (Cu)

A B
M14x1,5
5/8"-24

8 h7
17,5 16

28 SW 19

56,5 pin configuration:

A=+
B=-

Fig. 4: Temperature Sensor TS 01 - 28 - PT 1000

6.4 Pressure Sensors

6.4.1 Oil Pressure Sensor

Measuring range 0 - 6 bar or 0 - 10 bar

Over pressure 15 bar resp. 20 bar
Supply voltage 10 - 34 V DC
Output signal 4 - 20 mA
Storage temperature -25°C up to +85°C
Ambient temperature -25°C up to +85°C
Oil temperature -25°C up to +125°C
Protection grade IP 65
Vibration < 20 g, 10 - 300 Hz
Shock < 50 g, 11 ms half-sine wave
Tightening torque max. 25 Nm
Connection DIN 43650-A, 2-line system

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6 Sensors

27
G1/4"

Ø 19

M5
12
SW 19

22 48,8 26

Fig. 5: Oil Pressure Sensor

Max. Operating
Pressure Sensor EDV- No.
Pressure (bar)
DSO 01 - 6 600-00-058-00 6
DSO 01 - 10 600-00-058-01 10

6.4.2 Boost Pressure Sensors

The boost pressure sensors are also available in an additional housing with terminal
strip.

Measuring range 0 - 2 bar, 0 - 5 bar or 0 - 10 bar

Over pressure 4 bar resp. 10 bar resp. 16 bar
Supply voltage 12 - 36 V DC
Output signal 4 - 20 mA
Storage temperature -55°C up to +100°C
Ambient temperature -40°C up to +100°C
Protection grade IP 65
Vibration < 2 g, 5 - 500 Hz
Shock < 50 g, 11 ms half-sine wave
Connection DIN 43650-A or terminal strip, 2-line system

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6 Sensors

6.4.2.1 Boost Pressure Sensor with Plug

89 SW 24
12
2
G3/8"

Ø 30

33,5
30,5

53
124,7
PG9

Ø 19

Fig. 6: Boost Pressure Sensor with Plug

Max. Operating
Boost Pressure EDV- No.
Pressure (bar rel.)
DSL 01 - 2 600-00-057-00 2
DSL 01 - 5 600-00-057-01 5
DSL 01 - 10 600-00-057-02 10

6.4.2.2 Boost Pressure Sensor with Housing and Terminal Strip

57
125
29,5
113 6
10
4,5

SW 24
14

R
HEINZMANN
GmbH + Co.
G3/8"
52

G1/4"
80

Am Haselbach 1
30

D-79677 SchÎnau/Schw.
Germany
Phone: (07673) 8208-0
Telefax: (07673) 8208-88

15
30

27,5 91

Fig. 7: Boost Pressure Sensor with Housing

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6 Sensors

Max. Operating
Pressure Sensor EDV- No.
Pressure (bar rel.)
DSG 04 - 2 600-00-056-00 2
DSG 04 - 5 600-00-056-01 5
DSG 04 - 10 600-00-056-02 10

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7 Setpoint Adjusters

7 Setpoint Adjusters

With regard to the variety of applications, various setpoint adjusters are available for the
HEINZMANN digital speed governors of series Pandaros.

7.1 Setpoint Potentiometer SW 01 - 1 - b (1 turn)

(EDV- No.: 600 00 041 01)

Displacement angle approx. 312°

Resistance 5 kOhm
Temperature range -55°C to + 120°C
Protection grade IP 00

3/8" - 32 NEF - 2A
26
Ø 27
23

9,5

Fig. 8: Potentiometer SW 01 - 1 - b

7.2 Setpoint Potentiometer SW 02 - 10 - b (10- turn)

(EDV- No.: 600 00 042 01)

Displacement angle 10 turns

Resistance 5 kOhm
Temperature range -55°C to + 120°C
Protection grade IP 00

3/8" - 32 NEF - 2A
32
Ø 23
17

8,8

Fig. 9: Potentiometer SW 02 - 10 - b

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7 Setpoint Adjusters

On request, the potentiometers, as specified under 6.1. and 6.2. can be supplied with
analogue adjustment knob with lock in place of the standard rotating knob. In this case,
ordering specification is SW..-..-m.

Likewise, a clamping fixture can be installed instead of the knob. The ordering
specification will then be SW ..-..-k.

7.3 Setpoint Value Adjustment by Current Signal

For the speed setpoint value a current signal of 4 – 20 mA can be directly connected to the
control unit. If the signal fails, the governor will adjust minimum speed according to the
4 mA value or use a pre-programmed substitute value.

7.4 Digital Presetting of Setpoint Values

On condition that the governor is configured correctly, a digital setpoint source is possible
directly with two switch inputs (increase/decrease speed), e.g. digital synchronizing
manually or with PLC.

7.5 Setpoint Value Adjustment by Pedal

This unit is basically an angular position transducer that translates gas pedal positions into
a proportional current or voltage for 0 - 45° rotational displacement. The resulting output
can be used for speed setting. For more information refer to manual E 83 005 - e.

7.6 Pneumatic Setpoint Adjuster

If pneumatic setpoint adjustment is desired, the boost pressure sensors may be used to
supply the signals. For detailed specifications of these sensors refer to chapter 5.5.2.

Digital Governor Basic System PANDAROS V 19

 HEINZMANN®

8Control Unit DC 6 – 01..05

8 Control Unit DC 6 – 01..05

8.1 Specification

8.1.1 General

Supply voltage 12 V DC or 24 V DC
min. voltage 9 V DC
max. voltage 33 V DC
max. ripple voltage max. 10 % bei 100 Hz
Current consumption max. 7 A, and
max. 11 A for max. 60 Seconds
Permissible voltage dip at
maximum current consumption max. 10 % in control unit
Fuse protection of governor 12 A
Storing temperature -40°C up to +85°C
Operating temperature -40°C up to +80°C
Operating temperature LCD 0°C up to +50°C
optional -20°C up to +70°C
Humidity up to 98% at 55°C
Dynamic strength max. 2 mm at 10 up to 20 Hz,
max. 0,24 m/s at 21 up to 63 Hz
max. 7 g at 64 up to 2000 Hz
Shock 50 g, 11 ms- half-sine wave
Protection grade IP 00
Insulation resistance > 1 MOhm at 48 V DC
Weight approx. 0.5 kg
EMC EMC Directives: 89/33/EWG, 95/54/EWG
according to EMC Standards: ISO 11452-2
ISO 7637-2
ISO 7637-3
VDE 0879-3
EN 50081-2
EN 50082-2
further information on request
8.1.2 Inputs and Outputs

All inputs and outputs are protected against reverse-voltage and short circuit to battery
plus and minus.

20 Digital Governor Basic System PANDAROS V

HEINZMANN®

8 Control Unit DC 6 – 01..05

Speed input for inductive sensor, with

fi = 25 up to 9000 Hz, Ui = 0.5 up to 30 V AC
Temperature input for PT1000 / Ni1000 sensors
tolerance: < ±2°C at 0°C up to 130°C,
rest < ±4°C
Reference voltage setpoint adjuster Uref = 5 V ±1 %, Iref < 30 mA
Setpoint default analogue U = 0..5 V, Re = 100 kΩ, fg = 15 Hz
or I = 4 .. 20 mA, Re = 200 Ω, fg = 15 Hz

Setpoint default digital 1 U0 < 2 V, U1 > 6.5 V, Rpd = 100 kΩ

Setpoint default digital 2 U0 < 2 V, U1 > 6.5 V, Rpd = 4.75 kΩ,
oder Rpu = 4.75 kΩ oder Rpd = 150 kΩ
Digital input engine stop U0 < 2 V, U1 > 6.0 V, Rpd = 4.75 kΩ
or Rpu = 4.75 kΩ or Rpd = 150 kΩ
Actuator position sensing internal in actuator with reference feedback
analogue UReg.weg = 1.4 ..3.0 V, Uref = 8 V ±x %, Iref < 20 mA
digital only with HEINZMANN-StG and Bosch EDC
Drive output I < 7 A, I < 11 A für T < 60 s, PWM
Digital output failure lamp Isink < 0.3 A, Urest < 1.0 V, Ileck < 0.1 mA
Rpu = 4.75 kΩ oder Rpu = ∞, ground switched
Serial interface ISO 9141, RS 232 variable from 2.4 kbit/s up to 57.6 kbit/s
standard 9.6 kbit/s

Additional Inputs
only for DC 6 – 03..05 Ue = 0..10 V, Re = 20 kΩ, fg = 15 Hz
or Ue = 0..5 V, Re = 100 kΩ, fg = 15 Hz
or Ie = 4 .. 20 mA, Re = 200 Ω, fg = 15 Hz
or U0 < 2 V, U1 > 6.5 V, Rpd = 4.75 kΩ
or Rpu = 4.75 kΩ oder Rpd = 150 kΩ

Digital Governor Basic System PANDAROS V 21

 HEINZMANN®

8Control Unit DC 6 – 01..05

8.2 Measurements
101,5 31,5
5 91,5 5

5
5

HEI NZMANN
Am Haselbach 1
R

D-79677 Schönau/Germany
Phone: +49 (7673) 8208-0
Fax: +49 (7673) 8208-188
Multi Funct. Port
1

1
2

2
GND
PANDAROS
3

3
4

4
SHIELD
5

5
REF
Setpoint / MFP

FOR StG 6...10 ADD COIL UNIT!

6

6
7

7
GND
8

8
DC 6
9

9
10 11 12 13 14 15 16 17

10
11 12 13 14 15 16 17
STOP/DI
GND
250
240

SHIELD

FB-COM

FB-MEA

FB-REF
Actuator
18 19

18 19
DRIVE-

DRIVE+
20

20
21

21
+ 12A

to DC6
22 23

22 23

DRIVE-

DRIVE+
COIL UNIT FOR StG 6...10
to Actuator
24 25

24 25

DRIVE-

DRIVE+
CU-01

6 31,1
ca 34,7

12V/24V Type-Nr.

Serial No.

84,5

Fig. 10: Housing of Control unit DC 6-01..05 without Handprogrammer

Note: The terminals 1 to 3 are not available at the standard versions DC 6-01 and
DC 6-02.

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HEINZMANN®

8 Control Unit DC 6 – 01..05

101,5 31,5
5 91,5 5

5
5

H EI NZMANN
Am Haselbach 1
R

D-79677 Schönau/Germany
Phone: +49 (7673) 8208-0
Fax: +49 (7673) 8208-188
1

1
MFP
2

2
GND
3

3
4

4
Function
Window
SHIELD Escape
5

5
FOR StG 6...10 ADD COIL UNIT!
REF
Setpoint / MFP
6

6
7

7
GND
8

8
9

9
10 11 12 13 14 15 16 17

10
11 12 13 14 15 16 17
STOP / DI
GND

250
240

SHIELD
Feedback

ENTER
Actuator
-
18 19

18 19
Drive
+
-
20

20
21

21
PANDAROS
+ 12A

DC 6-PG
to DC6
22 23

22 23

DRIVE-

DRIVE+
COIL UNIT FOR StG 6...10
to Actuator
24 25

24 25

DRIVE-

DRIVE+
CU-01

6 31,1
ca 34,7

12V/24V Type-Nr.

Serial No.

84,5

Fig. 11: Housing of Control unit DC 6-01..05 with integrated Handprogrammer

Note: The terminals 1 to 3 are not available at the standard versions DC 6-01 and
DC 6-02.

Digital Governor Basic System PANDAROS V 23

 HEINZMANN®

8Control Unit DC 6 – 01..05

8.3 Mounting

When selecting the location, care should be taken for easy access in order to facilitate read-
out of the failure indication and replacement of the device under field conditions. Any
mounting position is admissible. When fitting the device directly on the engine, it should
be mounted using vibration absorbers.

24 Digital Governor Basic System PANDAROS V

HEINZMANN®

9 Actuators

9 Actuators

9.1 Design and Mode of Operation

Control Rod Travel

(up to 20 mm)

Feedbacksystem
(without optional)

Linear Solenoid System

Fig. 12: Sectional Drawing of Actuator

The Linear Actuators LStG 20 and LstG 40 are mounted directly onto the injection pump.

The Linear Actuator is driven by an electric linear operating magnet. The armature shaft of
this linear operating magnet is fixed to the control rod of the injection pump by a custom
specific connection. By variating energizing of the magnet the spring loaded armature
shaft is moved with the magnet's force working in the direction of maximum fuel quantity
and the spring force working in the direction of stop position.

The position of the control rod is sensed by a contactless working feedback system and
transmitted to the control unit. By this, the control unit is able to rapidly determine the
linkage adjustment that will be necessary in case of speed changes and to variate the
current accordingly. Optionally, this feedback system can be dropped. In this case, position
sensing is achieved by simply measuring the current of the magnet system. This sensing
method, however, is less accurate.

Optionally, the LStG 40 is also available equipped with an additional external stop lever,.
offering the possibility of executing an emergency shutdown. This will, however, require
to overcome the actuating electric force working in the direction of 100 %. So when
executing an emergency stop by means of the stop lever the voltage supply should be cut
off first.

Due to the fully enclosed mounting, the control linkage is completey protected which will
ensure a long and maintenance-free service life of the actuators.

Digital Governor Basic System PANDAROS V 25

 HEINZMANN®

9 Actuators

9.2 Installation

For the different pump systems, a variety of assembly kits is provided consisting mainly of
the adapter plate and the customer-specific linkage connection.

The assembly kits come with detailed assembling instructions which will help the user to
do the mounting easily by himself.

26 Digital Governor Basic System PANDAROS V

HEINZMANN®

9 Actuators

9.3 Specification

LStG 20 LStG 40

Maximum control rod travel 18 mm 21 mm

Spring power of back spring
in stop position approx. 15 N approx. 32 N
Spring power of back spring
in full position 25 N 50 N
Maximum positioning force approx. 30 N approx. 95 N
Maximum current consumption 6A 10 A
Current consumtion in operation 1 .. 3 A 3 .. 5 A
Coil resistance of governing magnet 1,7 Ohm 0,7 Ohm
Storage temperature -55°C up to +110°C -55°C up to +110°C
Ambient temperature in operation -40°C up to +90°C -40°C up to +90°C
Humidity up to 100 % up to 100 %
Protection grade IP 55 IP 55
Weight without adapter plate approx. kg approx. 4 kg

Digital Governor Basic System PANDAROS V 27

 HEINZMANN®

9 Actuators

9.4 Measurements

54,5
Adapter plate

70,5
43,5
120
42

50

17,5

116

84

Fig. 13: Actuator LStG 20

28 Digital Governor Basic System PANDAROS V

HEINZMANN®

9 Actuators

182,5
61 67
Pump
(customer side)

56
85

132
70

89
108
104

Stop Lever
(optional)

Fig. 14: Actuator LStG 40

Digital Governor Basic System PANDAROS V 29

 HEINZMANN®

10 Electrical Connection

10 Electrical Connection

The electrical connection possibilities are depending on the variation of the control unit.

10.1 Connection for variation DG 6-01 (Standard Generator)

Control Unit
DC .. 6-01

4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

Temperature Sensor Governor

on

Fuse
12 A
24V

Battery
LStG 40

LStG 20

Increase Speed

Decrease Speed
C 2
B 1

Common Alarm D 5
A 4
E 3

Run (open Engine Stop) Feedback

LStG 20
optional
LStG 40
Actuator

B
A

Magnetic Pickup IA ..

Fig. 15: Connection Diagram for Variation DG 6-01

30 Digital Governor Basic System PANDAROS V

HEINZMANN®

10 Electrical Connection

10.2 Connection for variation DG 6-02 (Standard General)

Control Unit
DC .. 6-02

4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

Temperature Sensor Governor

on

Fuse
12 A
Setpoint Potentiometer 24V
cw
max. 470 Ω
out
5 kΩ
ccw Battery
470 Ω
min.

LStG 40

LStG 20

Fixed Speed
C 2
B 1

Common Alarm D 5
A 4
E 3

Run (open Engine Stop) Feedback

LStG 20
optional
LStG 40
Actuator

B
A

Magnetic Pickup IA ..

Fig. 16: Connection Diagram for Variation DG 6-02

Digital Governor Basic System PANDAROS V 31

 HEINZMANN®

10 Electrical Connection

10.3 Connection for variation DG 6-03 (Extended Generator 1)

Control Unit
DC .. 6-03

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

Auxiliary Contact Governor

Generator Breaker on

Fuse
12 A
24V

15
16 Battery
14

Load Measuring Unit

LMG 03-S2

Temperature Sensor
LStG 40

LStG 20

C 2
Increase Speed
B 1

D 5
Decrease Speed A 4
E 3

Feedback
Common Alarm LStG 20
optional
LStG 40
Actuator

Run (open Engine Stop) B

A

Magnetic Pickup IA ..

Fig. 17: Connection Diagram for Variation DG 6-03

32 Digital Governor Basic System PANDAROS V

 HEINZMANN®

10 Electrical Connection

10.4 Connection for variation DG 6-04 (Extended Generator 2)

Control Unit
DC .. 6-04

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

16 A Governor
on
17
Synchronizer Fuse
SyG 02 12 A
24V

15
16 Battery
14

Load Measuring Unit

LMG 03-S2

Temperature Sensor
LStG 40

LStG 20

Setpoint Potentiometer

max.
cw C 2
470 Ω
out B 1
5 kΩ
ccw
470 Ω
min.
D 5
A 4
Selector Switch E 3
Analogue Accessory Units/
Setpoint Potentiometer Feedback
LStG 20
optional
LStG 40
Actuator
Common Alarm
B
A

Run (open Engine Stop) Magnetic Pickup IA ..

Fig. 18: Connection Diagram for Variation DG 6-04

Digital Governor Basic System PANDAROS V 33

 HEINZMANN®

10 Electrical Connection

10.5 Connection for variation DG 6-05 (Extended General)

Control Unit
DC .. 6-05

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

Oil Pressure Sensor

Governor
on
Boost Pressure Sensor

Fuse
12 A
24V
Temperature Sensor

Battery

Setpoint Potentiometer
cw
max. 470 Ω
out
5 kΩ
ccw
470 Ω
min.
LStG 40

LStG 20

Fixed Speed
C 2
B 1
Common Alarm
D 5
A 4
E 3
Run (open Engine Stop)
Feedback
LStG 20
optional
LStG 40
Actuator

B
A

Magnetic Pickup IA ..

Fig. 19: Connection Diagram for Variation DG 6-05

10.6 Harness

34 Digital Governor Basic System PANDAROS V

HEINZMANN®

10 Electrical Connection

Important: It is not possible to use all offered signals at the same time, because some
inputs have to be assigned differently depending on the variation.

Control Unit DC 6-01..05

+ - L1 L5

Battery
Sensors

L2 L6

Actuator Switch Inputs

40 50

L3 L7
60
30 70

20 80

10 90
0 100

Setpoint Adjuster Error Messages

L4 L10

Magnetic Pickup Communication

Fig. 20: Cable Designation

Digital Governor Basic System PANDAROS V 35

 HEINZMANN®

10 Electrical Connection

The allowed length and necessary cross-sections of the cables to connect are as follows:

L1 Power supply max. 15 m 2 x 2.50 mm²

L 2.1 Actuator feedback 3 x 0.75 mm²

L 2.2 Actuator drive up to 10 m 2 x 2.50 mm²
over 10 - 20 m 2 x 4.00 mm²

L 3.1 Setpoint potentiometer 3 x 0.75 mm²

L 3.2 4 - 20 mA input 2 x 0.75 mm²
L 3.3 0-5V 2 x 0.75 mm²
L 3.4 Synchronizer 2 x 0.75 mm²
L 3.5 Load measuring unit 2 x 0.75 mm²

L4 Magnetic pickup 2 x 0.75 mm²

L 5.1 Temperature sensor 2 x 0.75 mm²

L 5.2 Boost sensor 2 x 0,75 mm²
L 5.3 Oil pressure sensor 2 x 0.75 mm²

L 6.1 Engine stop 1 x 0.75 mm²

L 6.2 Increase speed 1 x 0.75 mm²
L 6.3 Decrease speed 1 x 0.75 mm²
L 6.4 other switch functions 1 x 0.75 mm²
(the switches have to be supplied with battery plus)

L7 Error message 1 x 0.75 mm²

(the error lamp has to be supplied with battery plus, ground is switched)

36 Digital Governor Basic System PANDAROS V

HEINZMANN®

11 Parametrization Possibilities

11 Parametrization Possibilities

The software for the HEINZMANN series Pandaros has been designed in a way that will
allow programming both at the HEINZMANN factory and by the engine manufacturer.

Since erroneous programming can cause considerable damages, full use should be made of
the level structure and the user masks.

As a principle, first programming should always be conducted by experienced personnel and

must be checked before first commissioning the engine. If possible, a HEINZMANN
specialist should be consulted when first programming is performed.

The following sections describe the possibilities of parametrizing the control unit:

11.1 Parametrization at the Factory

During final inspection at the factory, the functionability of the unit is checked by a test
programme. If the operational data for the control unit is available, the test programme is
carried out using this data. It is then only the dynamics data and if need be the fuel
limitations and sensors that will have to be calibrated on the engine.

11.2 Parametrization with the Hand Held Programmer 3

All parametrization can also be done by means of the hand held programmer
‘Programmer 3’. This handy device is particularly suited for development and series
calibration as well as for servicing.

11.3 Parametrization with the Keybord on the Control Unit

The parametrization is here the same as with the external hand held programmer 3.

11.4 Parametrization with the PC

Parametrization can also be conducted using a PC and the comfortable HEINZMANN

software DC DESK. As compared with the hand held programmer, it offers the great
advantage of having various curves graphically represented on the screen and being at the
same time able to introduce changes as well as of having time diagrams displayed without
an oscilloscope when commissioning the control unit on the engine. Furthermore, the PC
offers a better overview as the PC programme has a menu structure and allows to have
several parameters continuously displayed.

Digital Governor Basic System PANDAROS V 37

 HEINZMANN®

11 Parametrization Possibilities

Besides, the PC programme permits to save and download the operational data to and from
diskettes.

11.5 Parametrization with User Masks

Principally, parametrization may be performed with the help of user masks that have been
provided by HEINZMANN or may conveniently be created by the user himself. Within a
user mask, only those parameters are accessible that are actually needed.

11.6 Transferring Data Sets

Once parametrizing a particular engine model and its application has been completed, the
data set can be saved (in the hand held programmer or on a floppy disk). For other
applications of the same kind the data set can then be downloaded into the respective
control units.

11.7 Assembly Line End Programming

This type parametrizing is used by the engine manufacturer during the test bench run when
the control unit is programmed in accordance with the engine requirements as laid down in
the order.

38 Digital Governor Basic System PANDAROS V

HEINZMANN®

12 Starting the Engine

12 Starting the Engine - Brief Instructions

11.1 Adjust clearance of magnetic pulse pickup.

11.2 Check program with respect to relevant parameters: number of teeth, speed, etc.

11.3 Calibrate sensors and setpoint adjusters, if necessary.

11.4 Make autoadjustment of actuator.

11.5 Set point potentiometer in mid-position:

P - Gain to 50
I - Stability to 0
D- Derivative to 0

If the dynamic values have already been determined for an installation, they can be
programmed directly at this point.

Attention: Overspeed protection must be guaranteed!

11.6 Start engine and run it up to nominal speed using the set point potentiometer.

11.7 Increase gain (P-fraction) up to instability and reduce until stability is attained.
Increase stability (I-fraction) up to instability and reduce until stability is attained.
Increse derivative (D-fraction) up to instability and reduce until stability is attained.

With these values set, engine speed is to be disturbed briefly (e.g., by shortly
pressing the stop switch), and the transient oscillations are to be observed.

11.8 Check over the entire speed range.

If for maximum and minimum speed other values than the programmed ones should
result, this will be due to tolerances of the set point potentiometer. If the speed
derivation is not acceptable, it will be necessary to measure the setpoint source.

11.9 Gain-correction (P-correction) for gas engines resp. for variable speed governors
with larger speed ranges; adjust map if necessary.

11.10 Checking the remaining program items, e.g., starting fuel injection, ramp time, etc.

Digital Governor Basic System PANDAROS V 39

 HEINZMANN®

13 Order Information

13 Order Information

Control Unit:
Designation DC X .6 - 0Y - (PG)
X = used actuator type LStG 20 or LStG 40
Y = application variation 1 .. 5 (refer to the connection diagrams)
PG = when integrated Programmer is required, only

Before delivery, the control unit will be conformed on the hardware side to the application
variation inclusive the actuator type. While doing so, the analogue inputs are calibrated, if
necessary. The included software correspond to the application. All further adjustments as
e.g. teeth number, speed range, limitation curves, dynamic parameters, start procedure etc.
have to be set by the customer himself.

Actuator:
Here an actuator designation has to be given, as listed in chapter 8.

Magnetic Pickup:
Here an magnetic pickup designation has to be given, as listed in chapter 6.2.5.

Additional Sensors:
If additional sensors or a setpoint adjuster is necessary, the order informations can be taken
from the corresponding chapters.

Harness:
Generally it is recommended to produce the harness at HEINZMANN. Therefore the needed
cable length for each connections has to be given.

The wiring to the actuator and to the magnetic pickup has to be done by HEINZMANN
generally, because here plugs from HEINZMANN are used where the conntacts of the cables
have to be soldered.

The order designation of each cable can be taken from the chapter 10.6.

40 Digital Governor Basic System PANDAROS V

HEINZMANN®

14 Order Specifications for Manuals

14 Order Specifications for Manuals

There is no charge for our technical manuals ordered in reasonable quantities.

Order the necessary manuals on our speed governors from your nearest
HEINZMANN location.
(Please click on “HEINZMANN location” to see the list of our subsidiaries and agents in the
world).

Please include the following information:

• your name,
• the name and address of your company (you can simply include your business card),
• the address where you want the manuals sent (if different from above),
• the number(s) (as on front page bottom right) and title(s) of the desired manual(s),
• or the technical data of your HEINZMANN equipment,
• the quantity you want.

You can directly use the following fax-form for ordering one or several manuals.

We solicit comments about the content and the presentation of our publications. Please, send
your comments to:

HEINZMANN GmbH
Marketing Abteilung
Am Haselbach 1
D-79677 Schönau
Germany

Digital Governor Basic System PANDAROS V 41

Fax Response

Order for technical manuals

Fax-Hotline .. 49 7673 8208 194

 Please send me following manuals:

Quantity No. of the manual Title

 Please send me your new sales documentation about

( ) the HEINZMANN analogue governors. Application: .....................................................

( ) the HEINZMANN digital governors. Application: .....................................................

Company ........................................................................................................................................

Contact ...........................................................................................................................................

Department .....................................................................................................................................

Address .............................................................. Country/Code/Town ..........................................

Phone ................................................................. Fax .....................................................................

Activity ...........................................................................................................................................

Date ................................................................................