Jenbacher Technical Instruction No.

: 1502-0065
Documentation Heinzmann Controller for StG 10 StG 30 and , StG40Actuators

1. Function:___________________________________________________________2
1.1 Use and general function: 2
1.2 Protection functions: 2
2. Assembly:__________________________________________________________3
2.1 Wiring: 3
2.2 Terminal strip allocation: 4
3. Retrofitting PANDAROS to field systems: _______________________________5
3.1 Retrofitting PANDAROS to dia.ne systems: 5
3.2 Comparison of terminal strips when retrofitting: 5
3.3 Retrofitting PANDAROS to EMS 2000 systems: 5
3.4 Documentation when retrofitting: 6
4. Settings: ___________________________________________________________6
4.1 Current range: 6
4.2 Position settings auto adjust: 6
5. Cumulative failure transmitting output:__________________________________8
5.1 General: 8
5.2 Controller warnings / self-resetting: 8
5.3 Controller emergency shutdowns: 8
6. Troubleshooting: ____________________________________________________9
6.1 Failure message - warning: 9

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 Jenbacher Technical Instruction No.: 1502-0065
Documentation Heinzmann Controller for StG 10 StG 30 and , StG40Actuators

1. Function:

1.1 Use and general function:

The Heinzmann Pandaros controller is used in conjunction with the Heinzmann StG10, StG30 and
StG40 actuator and controls the position of the throttle valve. The controllers control electronics include a
powerful 16-bit microprocessor. The actual actuator position (voltage signal: approx. 1.4 V = 0 %, approx.
3.0 V = 100 %) is compared to the engine control setpoint position (current signal: 0-20mA). The
actuating variable calculated from the setpoint value and actual value is transmitted to the power output
transformer in the control electronics. This output then controls the engine in the actuator. The actual
controller program that the microprocessor uses is permanently stored in a flash EPROM.

Type designation: PANDAROS PDC 6-40.6-06-S1

An equipment redesign by Heinzmann (quarter 3 / 2004) has produced the following new type
designation: PANDAROS PDC 6-40.6-06-S1-A

The parameters for the controller have been factory-preset by the manufacturer to GE Jenbachers
specifications. Different sets of parameters are required to control the STG10, STG30 and STG40
actuators. The STG40 requires a higher parameter setting for the current limiter to achieve its higher
nominal moment.
For logistical reasons there are therefore two different GEJ part numbers with the relevant set of
parameters depending on the actuator type.

Pandaros TL 369160 for actuator STG10 with TL 118918 and STG 30 with TL 281814.
Pandaros TL 438222 for actuator STG40 with TL 305256.

1.2 Protection functions:

The servo amplifier is equipped with protection functions both for the actuator (current limiter) and the
auto-protection functions (short-circuit protection, etc.).

Short-circuit protection:
If a short circuit occurs in the power output side of the actuator circuit, the amplifiers output transformer is
switched off automatically.
The controller is pole-error protected and short-circuit protected at all the digital and analogue inputs and
outputs of the control electronics against the positive and negative of the power supply.

Overvoltage / undervoltage protection:

If the supply voltage exceeds 32 V or falls below 9 V, the amplifier is switched off and the failure
transmitting output is activated.

Current limiter:
A peak current of 6.4 A for a maximum of 5 seconds and a constant current of 3.2 A are permitted in
order to protect the StG10 and StG30 actuators from thermal overload. The permissible peak current for
the StG40 is 9.0 A for a maximum of 5 seconds and the constant current is 4.5 A. The controller
guarantees these limiting conditions by automatically reducing the current to the permissible constant
current within a maximum of 80 ms approx. 5 seconds after the permissible constant current has been

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exceeded. The power consumption of the actuator can be checked by measuring the current at the output
side of the actuator circuit.

The current limiter is only activated if the actuator is obstructed or overloaded. This is an
indication of the incorrect setting of a mechanical component (control rod assembly, throttle
valve) or a malfunction or that the nominal moment of the actuator is insufficient for the
application.

2. Assembly:

The controllers control electronics are contained in a metal housing (B x H x D = 165 x 105 x 65mm),
which is suitable for top-hat rail mounting. The connection is established via the terminal strip on the
circuit board.

2.1 Wiring:
Cable sets with prepared connectors (for actuators) are used to make the electrical connection with the
actuators.
TL 234658 StG 10 Type 2 and 3 engines Cable length approx. 9 m.
TL 234666 StG 30, StG 40 Type 6 engines Cable length approx. 11 m.

The connection with the actuators is established by means of two cables, L1 and L2, of equal length.
L1: 2-pole, 1.5 mm, shielded plastic-sheathed cable (engine connection)
L2: 3-pole, 0.75 mm, shielded plastic-sheathed cable (signal connection)

Both cables are led to the connection on the actuator in a common connector (MIL). The cable shields
must be led to the terminal strip on the controllers circuit board. The shield for the signal cable L2 must
be connected to the corresponding terminal strip (14 | GND). The shields for L1 and L2 must be earthed
at the entry to the module interface box.

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Documentation Heinzmann Controller for StG 10 StG 30 and , StG40Actuators

2.2 Terminal strip allocation:

Connections to the controller are made on a consecutively numbered circuit board terminal strip. A short
description of the terminal clamps is printed on the housing cover.
Part of the description of the terminal clamps on the housing cover has changed as a result of the
equipment redesign. The terminal strip table has been amended accordingly.
Pandaros terminal strip

Description of clamps Pin No. of Cable conductors

Pin Function (as stated on cover) actuator for L1 and L2
H Not in use! CANH
L Not in use! CANL
1 Not in use! P2
2 Not in use! P1
3 Not in use! 0V
4 Not in use! Tmp
5 Shield for mA signal 0V / GND (Shield)
6 Not in use! +5V
7 mA signal setpoint (+) SpA
8 mA signal setpoint (-) 0V (GND)
9 Dig. input for auto adjust SpD
(bridge to Terminal No. 11) (Closing contact symbol)
10 Failure transmitting output Err (Lamp symbol)
11 Dig. input for servomotor stop Stp
(bridge to Terminal No. 9 for (STOP / DI)
actuator - auto adjust)
12 Not in use! 0V (GND)
13 Not in use! Pu
14 Shield for position signal 0V / GND (Shield) Connector Shield for L2
housing
15 GND for StG position sensor FbC (FB-COM) E 3 L2
16 StG position signal FbM (FB-MEA) A 2 L2
17 Power supply for StG position FbR (FB-REF) D 1 L2
sensor
- Not in use! 0V (GND)
18 For PDC 6-40.6-06-S1-A:
Bridge to Terminal No. 23 Act + (DRIVE+)
For PDC 6-40.6-06-S1:
Bridge to Terminal No. 22 Act - (DRIVE-)
19 For PDC 6-40.6-06-S1-A:
Bridge to Terminal No. 22 Act - (DRIVE-)
For PDC 6-40.6-06-S1:
Bridge to Terminal No. 23 Act + (DRIVE+)
20 0 V supply Batt - (-)
21 +24 V supply Batt + (+)
22 For PDC 6-40.6-06-S1-A:
Bridge to Terminal No. 19 DRIVE- to DC6
For PDC 6-40.6-06-S1:
Bridge to Terminal No. 18 DRIVE- to DC6
23 For PDC 6-40.6-06-S1-A:

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Documentation Heinzmann Controller for StG 10 StG 30 and , StG40Actuators

Bridge to Terminal No. 18 DRIVE+ to DC6

For PDC 6-40.6-06-S1:
Bridge to Terminal No. 19 DRIVE+ to DC6
24 Actuator-engine line 1 DRIVE- to Actuator B 1 L1
25 Actuator-engine line 2 DRIVE+ to Actuator C 2 L1

3. Retrofitting PANDAROS to field systems:

3.1 Retrofitting PANDAROS to dia.ne systems:

The PANDAROS controller (TL 369160 / TL 438222) is fully compatible with the Alge servo amplifier (TL
319169). The electrical connection of the Pandaros is established as described in Point 3.2 Comparison
of terminal strips when retrofitting. The controller must also be switched off during engine standstill,
according to the current design of new modules, when these are being retrofitted.

3.2 Comparison of terminal strips when retrofitting:

Alge servo amplifier (TL- No. 319169) and Heinzmanns Pandaros controller (TL- No. 369160 / TL - Nr.
438222) Fa. Heinzmann.

Alge servo amplifier Pandaros PIN No. of Cable L2

Function Pin No. / Description PIN No. actuator (3 x 0.75)
Shield for position signal X9: 1 / Earth symbol 14 Connector Shield
housing
Power supply for StG position X9: 2 / +12 V 17 D 1
sensor
StG position signal X9: 3 / Pos. 16 A 2
GND for StG position sensor X9: 4 / GND 15 E 3
mA signal setpoint (+) X9: 5 / +mA 7
mA signal setpoint (-) X9: 6 / +mA 8
Shield for mA signal X9: 7 / Earth symbol 5
Opening contact signal relay X9: 8 / Opening contact
Base contact signal relay X9: 9 / Base
Closing contact signal relay X9: 10 / Closing contact

Alge servo amplifier Pandaros PIN No. of Cable L1

Function Pin No. / Description PIN No. actuator (2 x 1.75)
+24 V supply X10: 1 / +24 V 21
0 V supply X10: 2 / - 20
Shield for engine X10: 3 / Earth symbol Connector Shield
housing
Engine 1 X10: 4 / M1 24 B 1
Engine 2 X10: 5 / M2 25 C 2
Shield X10: 6 / Earth symbol

3.3 Retrofitting PANDAROS to EMS 2000 systems:

The controller setpoint for the EMS 2000 is 0 200 mA and the Pandaros setpoint input range is limited
to 0 20 mA. The 0 200 mA output setpoint signal of the EMS 2000 is adjusted to a 0 20 mA setpoint
signal by means of a shunt resistor and an active signal transducer with 3-way galvanic separation (input

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/ output / supply). At the shunt resistor a 0 5V voltage signal is generated from the 0 200mA signal
and adjusted to a 0 - 20 mA setpoint signal by the signal transducer.

The composite part number TL 415434 when retrofitting the EMS 2000 is made up of the necessary
shunt resistor and the signal transducer. The PANDAROS controller is not included in this composite part
number.

3.4 Documentation when retrofitting:

When retrofitting, the electrical engineering department (Elektrokonstruktion) must be contacted so that
existing electrical circuit diagrams can be updated.

4. Settings:

As supplied, the preset 0% and 100% position of the controller is only approximate. All other settings,
such as control circuit amplification and current limitation have already been adjusted to the optimum
value for operating with the STG10, STG30 and STG40. It is essential that the 0% and 100% position is
set accurately before the engine is operated for the first time. The setting is made by means of an auto
adjust function, i.e. when a wire jumper is connected to the Pandaros controller the actuator is adjusted
automatically for the 0% and 100% position.

The auto adjust function must be carried out each time the controller or the actuator is replaced. An auto
adjust is also required when the Pandaros is retrofitted to a field system and mechanical changes are
made, e.g. adjustments to the control rod assembly!

4.1 Current range:

The Pandaros must be selected for the analogue position setpoint with a current signal in the range of 0
20 mA. The setpoint cannot be switched from 0 20 mA to 0 200 mA for EMS 2000 systems, as is the
case with the Alge servo amplifier (TL No. 319169).

4.2 Position settings auto adjust:

Because of manufacturing tolerances for the position feedback system and the throttle valve rod
assembly the end positions must be set on first use, after the rod assembly has been adjusted. The
actual control range adjustment is set using the Pandaros by automatically adjusting the throttle valve
actuator (STG10, STG30, STG40) during engine standstill.
The throttle valve and the control rod assembly must be properly set by mechanical means in conjunction
with the actuator before the auto adjust can take place. The throttle valve and the control rod assembly
must not be obstructed or stiff.

Conditions for automatic adjustment of the 0% and 100% position:

The controller must be connected to the power supply. To carry out the auto adjust, you need to have a
wire jumper between terminals No. 9 and No. 11 of the controller. Another requirement for the adjustment
is that the engine should be at a standstill and no analogue setpoint should be produced (0 mA). If the
setpoint does not equal 0 mA during the adjustment procedure, the controller will perform an emergency
shutdown and the Pandaros will not be ready for operation. The Pandaros will not be ready for operation
again until the setpoint is 0 mA and the voltage has then been reset. The auto adjust can then be carried
out successfully. If the controller performs an emergency shutdown during an auto adjust, a new auto
adjust must always be carried out once the fault has been rectified.

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Triggering automatic adjustment for the 0% and 100% position:

Once the above conditions have been met, the auto adjust procedure can start. A wire connection must
be established for at least 10 seconds continuously between terminal No. 9 on the controller and terminal
No. 21, the BATT+ of the 24V DC power supply, without interruption. For operational safety reasons, the
wire must first be connected to terminal No. 9 before the connection is made to the power supply. The
auto adjust procedure is successfully completed after approx. 10 seconds. During this time the actuator
runs through the entire possible adjustment range from 0% to 100%. The actuator holds the 0% position
for approx. 5 seconds and then the 100% position, also for about approx. 5 seconds. At the same time
the adjustment range is initialised and the 0% and 100% end position is stored by the microprocessor in
the control electronics. Once the adjustment has been completed within about 10 seconds, it is essential
to break the connection between terminal No. 9 and the +24V DC terminal No. 21. As a precautionary
measure, the connection must first be broken at the 24V DC terminal No. 21. If the connection between
terminal No. 9 and the +24V DC terminal is broken first, this means that the auto adjust procedure will
have to be repeated.
The wire jumper between terminals No. 9 and No. 11 is only needed so that the + 24V DC terminals are
simultaneously positioned at the digital inputs of terminals No. 9 and No. 11 during the auto adjust
procedure. As long as the + 24V DC potential is not present at terminals No. 9 or No. 11, the wire jumper
is not relevant to the operation of the actuator. Under the conditions described above, this connection
must not therefore be removed.

Operation of the digital input at terminal No. 11 Servomotor Stop:

A potential of +24V DC at terminal No. 11 switches the controllers motor output to stop, i.e. the actuator
remains at the 0% position, irrespective of the current setpoint position. This is the trigger for auto adjust.

Operation of the digital input at terminal No. 9:

A potential of +24V DC at terminal No. 9 triggers auto adjust for the 0% and 100% position. However, this
is conditional on the digital input Servomotor Stop (terminal No. 11) being switched to + 24V DC
beforehand or simultaneously.

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5. Cumulative failure transmitting output:

5.1 General:
The controller has a cumulative failure transmitting outlet (warning and emergency shutdown), in the form
of a group alarm via a switching transistor output. When an internally monitored failure occurs, the
transistor switches over and internally connects the failure transmitting output (terminal 10) to the earth
for the power supply (0V | terminal 20. Pandaross internal diagnosis system can distinguish between
self-resetting error warnings and errors which will result in emergency shutdown of controllers output
stage and the actuator motor.
This cumulative failure transmitting output (warning and emergency shutdown) is integrated by means of
a pull-up resistor directly into the dia.ne AMM as warning number 1192 with the text Actuator/Controller
Failure (closed-circuit principle). In general, controllers in new installations have been switched off during
engine standstill since the year 2000 to extend their service life. As the controller is not activated during
engine standstill (no power supply), the controllers cumulative failure transmitting output is only
monitored by the dia.ne AMM when the engine is running.

5.2 Controller warnings / self-resetting:

A warning is issued via the controllers failure transmitting output when:
- the deviation between the setpoint position and the actual position is more than one second greater
than 10% of the normal route.

- The power supply is not in the permissible range of 9 to 32V DC.

The failure transmitting output is automatically reset when the controller data are again within the
defined error limits. The current warning on the dia.ne AMM can then be reset.

5.3 Controller emergency shutdowns:

An emergency shutdown of the controller occurs in the cases of error as described and is indicated by the
failure transmitting output:
- Fault in the actuators feedback system (defective position feedback, cable break or actuator not
connected or plugged in).
- Fault in automatic adjustment procedure.
- Internal fault in controllers electronics.

In the event of an emergency shutdown the controller blocks the actuator at the 0% position. The fault
must first be rectified and the controllers active failure transmitting output reset so that the actuator can
be restarted. The controller is reset by resetting the power supply and released for operation. Resetting is
done by switching the controllers power supply off and on again and is only necessary in installations in
which the controller and the actuator can still be operated during engine standstill.
Since the year 2000, controllers in new installations have been switched off during engine standstill in
order to extend the service life of the controllers and actuators. It is not necessary to reset the power
supply, as described above, during engine standstill after rectifying a fault as the controller has already
been switched off while the fault was being rectified. On engine startup the controllers power supply is
automatically switched on again with the ignition request and the cumulative failure transmitting output is
reset at the same time. It is possible to operate the actuator again, and the current Warning No. 1192 on
the dia.ne AMM can be reset.

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6. Troubleshooting:

6.1 Failure message - warning:

Message text and number Error Solution

ACTUATOR/CONTROLLER
FAILURE Emergency shutdown - controller:
1192
Fault in the actuators feedback Inspect cabling from controller to
system, actuator not connected or actuator and check connector; cable
plugged in; break or short circuit;

Check the actuator for possible

defective position feedback
(electronics), i.e. voltage signal at
terminal 16 (FB-MEA) as measured
against terminal 15 (FB-COM) is
outside the set range :
at 0% approx. 1.4 V DC
at 100% approx. 3.0 V DC
The reference voltage at terminal 17
(FB-REF) measured against
terminal 15 (FB-COM) is approx.
8.0V DC in normal operation

- Remedy: replace actuator

Fault in automatic adjustment Inspect cabling; repeat automatic

adjustment in accordance with the
TI; actuator should not be
mechanically blocked, check
smooth operation;
Controller setpoint must not
exceed 0 mA during adjustment.

Defective internal electronics Inspect cabling; repeat automatic

adjustment in accordance with the
TI; actuator should not be
mechanically blocked, check
smooth operation;

- Remedy: replace Pandaros.

Error in analogue setpoint; Check the analogue setpoint

signal setpoint is outside the 0 - 21 signal for the actuator position (mA
mA DC range. signal);

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check the cabling from the controller

to the output module of the engine
control system:
defective module, short circuit;

Pandaros controller input faulty.

- Remedy: replace Pandaros.

ACTUATOR/CONTROLLER Controller warnings - self-

FAILURE resetting:
1192
Deviation setpoint / actual position Check control rods and check
>10% for longer than 1 second that throttle valve is operating
smoothly and is securely seated;
Inspect the end position of the
throttle valve and check the
adjusting screw for the mechanical
stop;
Excessive forces acting on the
throttle valve, nominal moment
being exceeded, resulting in
increased deviation between
setpoint / actual position;
Inspect cabling from controller to
actuator; cable break, short circuit or
actuator not connected;

Overvoltage / undervoltage of 24V Check 24V DC power supply and

DC power supply cabling;
Error in internal electronic power Check for blown fuse in interface
supply (5V) cabinet;
Check the internal release relay
(ignition) during engine standstill
the controller and the actuator are
switched off;

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