Ecg PDF

KENR6237
08 March 2007
Special Instruction
Operation of the ECG Software ........................ 18
Hardware requirements ................................. 18
Installation of the Hardware ........................... 19
Installation of the ECG Software ................... 19
Basic Software Operation ................................. 20
Operating the ECG Software ......................... 20
Progress Display Screen ............................. 21
Navigating Around the ECG Software ........... 21
Software Menus and Options ............................ 21
File Menu ....................................................... 21
Save ECG to Cal to File .............................. 22
View Cal File Comments ............................. 24
View Text File ................................................ 25
Convert Commands ....................................... 25
Convert ECG Cal to Text ............................. 25
Convert Cal File to Text ............................... 25
Convert Cal File to Strategy ........................ 26
Calibrate Menu .................................................. 27
Download Cal File to ECG .......................... 27
Compare ECG Cal to File ........................... 28
Calibration Wizard ....................................... 29
Monitor Menu .................................................. 32
Parameter View ........................................... 32
Parameter Plot ............................................ 33
Make PID Gain Adjustment from the Plot
Display window ........................................... 34
Change Plot Setup ...................................... 35
Display Faults .............................................. 35
Control Strategy .......................................... 36
Parameter List ............................................. 36
Configure Menu .............................................. 38
Configure the Serial Port ............................. 38
Configure the Demonstration Mode ............ 38
Configure a Custom Serial Port ..................... 39
Help Menu ...................................................... 39
Help Topics .................................................. 39
About ACT ................................................... 40
User Manual .................................................. 40
Calibrating the Features of the ECG ................. 40
The Calibration Guide ....................................... 40
Calibration Categories ................................... 41
Calibrating the Controller ............................... 41
Saving a Calibration Set to a File .................. 42
Calibrating the Controller with a Saved
Calibration File ............................................. 42
Understanding the Calibration Parameters of the
ECG ................................................................. 42
Configuration Modes for the Switch ................. 43
Engine Start Calibration Parameters .............. 45
Glow Plug Control .......................................... 45
i02589674
Perkins Electronic Controlled

Governor
SMCS Code: 19084
400 Series Industrial Engines

(S/N: HB, HD, HH, HL, HN, HP, HR, GG ,
GH, GJ, GK, GL, GM, GN, GP, GQ
Table of Contents
Introduction ........................................................... 2
Understanding the System ................................... 2
Components of the Electronic Controlled Governor
(ECG) .................................................................. 2
Controller ........................................................... 2
Speed Sensor ................................................... 3
Actuator ............................................................. 3
ECG Software ................................................... 3
Programmable Features ................................... 4
Selection Options for Engine Speed .............. 4
Installing the Hardware ..................................... 4
Wiring Guidelines .......................................... 5
Wiring Lengths ............................................... 5
Installation of the Controller .............................. 5
Controller Wiring ............................................ 6
Basic Installation for the Control System for 1500
rpm and 1800 rpm ....................................... 8
Installation of the Speed Sensor ....................... 8
Engine Speed Setpoint Wiring Trim Analog
Input ................................................................ 9
Switched Inputs for the Engine Speed
Setpoints ......................................................... 10
Switch Wiring .................................................... 11
Single Switch Mode ....................................... 11
Two-Speed Mode .......................................... 11
Three-Speed Mode ........................................ 12
Four-Speed Mode .......................................... 12
Glow Plug Control Wiring .................................. 13
Installation of the Wiring for the Glow Plug
Control ......................................................... 13
Autocrank Wiring ............................................... 14
Installation of the Autocrank Wiring ............... 15
Auxiliary Output Wiring ...................................... 16
Engine Protection Input Wiring .......................... 17
Autocrank ....................................................
Diagnostic Calibration Parameters ....................
Engine Protection Input .................................
Actuator Calibration Parameters .......................
Auxiliary Outputs ...........................................
Droop Governing ...........................................
Troubleshooting .................................................
Governor Gain Calibration Parameters ..........
PID Gain Settings Response Plots ................
Troubleshooting Guidelines ...........................
Fault Codes ...................................................
Flow Chart for the Calibration Setup and
Configuration Parameters ...........................
Glossary of Terms .............................................
Speed sensor
45
46
46
47
47
48
48
48
48
49
50
Actuator
Calibration software
Controller
51
58
Introduction
Reference: General Information
NOTICE
Do not perform any procedure that is outlined in this
publication until you have read the information and
understand the information.
An engine overspeed device, independent of the

electronic controlled governor (ECG), must be
provided to prevent loss of engine control that
may result in personnel injury or death.
Illustration 1
g01297677
The controller for the ECG is an electronic engine

governor that provides a means of controlling and
limiting engine speed by adjusting the fuel control
lever with a proportional actuator. The controller for
the ECG may be programmed to operate at four
different speeds. The controller for the ECG also
operates in isochronous mode or droop mode. The
droop mode can be selected by the operator up to
8%.
The electronic controlled governor (ECG) provides a

means of controlling the engine speed by adjusting
the fuel control lever with an actuator.
Understanding the System

A microprocessor based controller processes the
signal from the speed sensor. The signal that is
received from the speed sensor is then compared to
the desired speed setting.
The controller for the ECG is programmed by the

software. The controller has no manual adjustments.
The output of the controller is a pulse width modulated

signal. The output signal drives a proportional
actuator. The actuator is connected to the engines
fuel control lever. The actuator converts the signal
to an output shaft position that is proportional to the
duty cycle of the pulse width modulated signal.
The ECG provides isochronous governing. The
engine speed is maintained at a setting regardless of
the load through a wide speed range.
Components of the Electronic

Controlled Governor (ECG)
The four main components of ECG are shown below:
Controller
Speed Sensor
The actuator is mounted on the engine in place of

the stop solenoid. The actuator acts directly on the
fuel rack.
Note: The actuator has the same functionality as the
stop solenoid.
ECG Software
Illustration 2
g01297366
A typical view of the speed sensors
The ECG monitors the engine speed continuously.

Engine speed is received through the use of a sensor.
The sensor uses the teeth on the flywheel in order to
monitor the engine speed.
Actuator
Illustration 3
g01297741
Illustration 4
A typical view of the actuator
Typical view of the ECG software
The actuator converts the pulse width modulated

signal that is received from the controller to an output
shaft position that is proportional to the duty cycle of
the pulse width modulated signal.
g01297765
The ECG software is designed to monitor the

controller. The ECG software will calibrate the
controller for the ECG. For further details of system
requirements and software requirements, contact
your Perkins dealer or your Perkins distributor.
Programmable Features
Table 1
Feature
Description
Additional Hardware
Actuator current protection
Protects the actuator from burning out
No
Autocrank
For remote operation of engines when using an auxiliary output
Yes
Auxiliary output
Two outputs that can be configured to drive lamps or relays
Yes
Droop governing
Allows for speed governing that is not isochronous
No
Engine protection input
Protects against adverse conditions such as engine oil pressure or

excessive coolant temperature
Yes
Engine start calibration
For engines that require special start-up operation such as warm

up speed, reduced governor gains or missing speed signal
No
Glow plug control
For enhancing cold start capability by using an auxiliary output
Yes
Overspeed/Underspeed
Protection
No
Proportional Integral
Derivative Gain adjustment
(PID)
Allows the governor response to be adjusted by the operator
No
Switched speed setpoint

inputs
Allows for multiple speed settings by using switches
Yes
Universal speed inputs
Speed input is compatible with magnetic pickup(1)
Yes
(1)
Refer to Table 2 for further information on available engine speed selection options.
Selection Options for Engine Speed
The ECG expands the Perkins line of programmable

engine governors in order to meet the requirements
of the customer.
The selection options for engine speeds that are

available are shown in Table 2.
The ECG has an advanced input capability and an

advanced output capability combined with a flexible
configuration that will permit the controller to adapt to
a variety of applications for governing of the engine.
Table 2
Description
Selection Options for

Engine Speed
The programmable features that are available with

the ECG are shown in Table 1.
No analog input
Use a speed switch in

order to select up to four
different speeds
The ECG software must be correctly installed in

order to configure the selected programmable
feature. To incorporate any of the programmable
features, refer to this Special Instruction, Perkins
Electronic Controlled Governor, Installing the
Hardware section of this manual. To calibrate any of
these programmable features, refer to this Special
Instruction, Perkins Electronic Controlled Governor,
Calibrating the Features of the ECG section of this
manual for further details.
Speed trim
Use a speed potentiometer

(analog output) in order
to trim the speed switch
selected set speed
Installing the Hardware

The hardware for the ECG will require setup.
Note: The hardware that is required for optional
features is supplied by the OEM.
Note: The hardware that is required for the

programmable features is supplied by the OEM.
In order to install the main components, refer to the

following items:
Special Instruction, Perkins Electronic Controlled
4. Use the correct gauge of wire and the correct

length of wire. Refer to Table 4 for the correct
gauge and the correct length of wire. Excessive
length of wire or the incorrect gauge of wire may
cause increased wire resistance. Increased wire
resistance can limit the current to the actuator.
Limiting the current may prevent full actuator
travel. Increased resistance in the wiring can also
result from poor wiring. It is important to use good
quality terminations and the correct technique for
crimping during wiring. Use Tooling (A) in order to
use good terminations. Use Tooling (B) in order to
crimp the terminal to the wire. Terminations must
be resistant to moisture in order to prevent a short
circuit and corrosion.
Governor, Wiring Guidelines

Governor, Installation of the Controller

Governor, Installation of the Speed Sensor
Wiring Guidelines
Table 3
Part Number
Description
20198
Connector kit
CH11155
Crimping tool
Wiring Lengths
The controller for the ECG must be installed in

a location when the effects of vibration and the
temperature is within the specified ranges.
Table 4
Wiring Specifications
Gauge
The temperature of the controller must be within the

following range:
The temperature range is 40 to 85C (104 to 153F).
20 m (66 ft)
1.50 mm2 (AWG 16)
10 m (33 ft)
1.0 mm (AWG 18)
6.7 m (22 ft)
The vibration of the controller must be within the

following range:
Length
2.50 mm (AWG 14)

2
The recommended gauges for the wire and the

maximum lengths of connecting wires for different
sizes of actuators or the ECG is shown in Table 4.
The wire length is calculated by using the total length
of wire that is used to connect the actuator to the
controller and from the controller to the power supply.
Random vibration ..................... 6 G at 40 to 2000 Hz

Refer to this Special Instruction, Perkins Electronic
Controlled Governor, Installation of the Controller
for further information on the dimensions of the
controller.
Note: Construct the wiring harness with a cable that

is two core. The cable must be shielded. The cable is
preferably shielded with foil.
1. Install the controller for the ECG.

2. Connect the power leads directly to a switched
power source (battery). Install a 10 amp slow blow
fuse in the battery wire.
Installation of the Controller

The dimensions of the controller are shown in
Illustration 5. The J1 connector is gray in color. The
J2 connector is black in color.
3. Install a shielded cable in order to receive the

external speed signal. One end of the shield
should be connected to the wire for the battery
ground. The use of convoluted tubing, conduit or
other wire shielding is recommended in order to
reduce the possibility of mechanical damage to
wires. Avoid routing wires near sharp edges or
near locations that can cause the wires to be
pinched or damaged.
Controller Wiring
Illustration 6
g01300072
Typical view of the J1 connector
Illustration 7
g01299544
Illustration 5
Typical view of the J2 connector
A view of the dimensions of the controller
Refer to Table 6 for the J1 pin locations. Refer to

Table 6 for the J2 pin locations.
Table 5
Dimensions of the Controller

1
94 mm (3.70 inch)
101.6 mm (4.0 inch)
7.39 mm (0.291 inch)
75 mm (2.953 inch)
117.04 mm (4.608 inch)
101.6 mm (4.0 inch)
36.245 mm (1.427 inch)
g01300075
Table 6
Function
Remarks
Pin Information
Actuator Output
ACT+ (J1-5), ACT- (J1-8)
Analog Input
APP (J2-12), Vref (J2-11), RTN (J2-2)
Auxiliary Output
Aux (J2-4), Vbat (J1-9)
Low Side Driver
Auxiliary Output #2
Aux 2 (J2-3), Vbat (J1-9)
Low Side Driver
Battery
VBAT (J1-9), GND (J1-4)
Engine Protection Input
EPSW (J2-9), GND (J1-4)
Switch to ground
ACT Connector
RCV (J1-12), TXD (J1-1), Vbb2 (J1-11), GND2

(J1-2)
Speed Signal Input
RPM+ (J1-10), RPM- (J1-3)
Switched Inputs
SW1 (J2-7), SW2 (J2-8), Vbat (J1-9)
Switch to Vbat
Basic Installation for the Control System for 1500

rpm and 1800 rpm
g01300420
Illustration 8
(1) J1 connector (gray)
(2) Actuator
(3) Speed sensor
(4) Battery ground -ve 12v

(5) Battery +ve 12v
(6) Speed selection switch
The controller for the ECG can be installed by using

the wiring diagram. The wiring diagram is shown in
Illustration 8.
The speed selection switch (6) enables the engine
speed to be switched between two set speeds.
Installation of the Speed Sensor

The speed sensor may be installed in various
positions. Contact your OEM for further information.
(7) J2 connector (black)
Engine Speed Setpoint Wiring Trim

Analog Input
Illustration 9
g01301437
Typical example of an installed speed sensor

Illustration 11
The speed sensor is a magnetic pickup sensor that

can be used with the ECG. The speed sensor is
installed opposite a driven gear. The speed sensor
transmits a signal when the gear tooth interrupts the
path of the magnetic flux. The speed sensor must
be installed to a rigid surface in order to reduce
vibration. Excessive vibration may cause erroneous
signals that may result in unreliable performance.
g01302234
(1) Controller
Illustration 12
g01343599
(1) Controller
The controller for the ECG features an analog speed

input.
Illustration 10
In order to incorporate this feature, the analog

input must be wired to an external potentiometer.
Potentiometer resistances of 3 k to 5 k ohms are
recommended. Refer to Illustration 11 for further
information.
g01301436
(1) Controller
A shielded twisted wire must be used for all speed

sensor wiring. The shielded wire must be grounded
to the controller for the ECG. Refer to Illustration 10
for further information.
In order to calibrate the parameters of this feature,

refer to this Special Instruction, Perkins Electronic
Controlled Governor, Calibrating the Features of the
ECG for further information.
Non-potentiometric analog voltages may also be used
in order to command set speed. The analog voltage
must not exceed 5 volts. The Non-potentiometric
analog voltage must be connected. Connect the
analog voltage to the battery + on the J2-12 pin.
Connect the analog voltage to the battery ground
- on the J1-4 pin. Refer to Illustration 12for further
information.
Switched Inputs for the Engine Speed

Setpoints
The controller for the ECG has two switched inputs
for multiple speed inputs. The two switched inputs
are used for obtaining more than one speed for
governing the engine.
In order to incorporate these switched inputs,
determine the speed mode that is required for the
application. On determining the speed mode, select
the hardware for the switch that is best suited for
the application. The hardware for the switch is not
provided by Perkins. Consult your OEM for further
advice on the hardware for the switch.
The four speed modes that are available for the
application are shown in the following list:
Single-speed
Two-speed
Three-speed
Four-speed
Choose a switch that is designed for low currents
with a range of 5 to 20 mA. Avoid choosing a switch
that is designed to use high current devices that rely
on the current to clean the switch contacts. A dry
circuit switch is recommended.
The speed select switch is typically installed on the
control panel.
Controlled Governor, Switch Wiring for further
information on installing the speed select switch.
On installing the speed select switch, calibrate
the Speed Setup parameters. Refer to this
Governor, Operation of the ECG software for further
information.
10
Switch Wiring
Single Switch Mode
g01344532
Illustration 13
Typical example of a wiring diagram for the single switch mode
(1) Controller
If a single speed mode is selected for the application,

no switch is required. A wiring diagram of the single
switch mode is shown in Illustration 13.
Two-Speed Mode
g01302347
Illustration 14
Typical example of a wiring diagram for the two-speed mode
(1) Controller
(2) Speed 1 (No connection)
A toggle switch is used in order to select two set

speeds. A wiring diagram of the two-speed mode is
shown in Illustration 14.
11
(3) Speed 2
Three-Speed Mode
g01344536
Illustration 15
Typical example of a wiring diagram for the three-speed mode
(1) Controller
(2) Speed 1 (No connection)
(3) Speed 2
(4) Speed 3
A three-position rotary switch is used in order to

select three set points. A wiring diagram of the
three-position rotary switch mode is shown in
Illustration 15.
Four-Speed Mode
g01344538
Illustration 16
Typical example of a wiring diagram for the Four-position rotary switch
(1) Controller
(2) Speed 1
(3) Speed 2
(4) Speed 3
(5) Speed 4
12
A four-position rotary switch with two diodes is used

in order to select four set speed. The diodes that can
be used in the four-speed switch mode are shown
in the following list:
1N4001
1N4002
1N4007
A wiring diagram of the four-position rotary switch
mode is shown in Illustration 16.
Glow Plug Control Wiring

The ECG offers a feature for the glow plug for the
use on remote starting or automatic starting. Contact
your Perkins dealer or your Perkins distributor for
further details.
Either of the two auxiliary outputs may be configured
for operating the glow plug.
Installation of the Wiring for the Glow Plug
Control
g01302721
Illustration 17
Typical example of the wiring for the glow plug control
(1) Controller
(2) Autostart switch input
(3) Auxiliary output

(4) Glow plugs
Install the wiring to the autostart switch. Connect the

input for the controller on the ECG to (2) (switch to
vbat).
13
Install the wiring to the glow plug relay on the engine.

Connect the positive side of the coil on the relay to
the Vbatt+ connection. Connect the negative side of
the coil to either auxiliary output J2-3 or J2-4. This
depends on the configuration of the auxiliary outputs.
Connect the power supply side of the relay switch to
the Vbatt+ connection. Connect the remaining side of
the relay switch to the input of the glow plugs.
Once the input for the ECG is wired, the parameters
require calibration. Refer to this Special Instruction,
Perkins Electronic Controlled Governor, Calibrating
the Features of the ECG.
NOTICE
If using the glow plug control feature, ensure that the
ECG controller is calibrated for the glow plug control
feature prior to connecting the ECG controller.
If the ECG controller is not calibrated for the glow
plug feature and the glow plug relay is connected,
the glow plug may switch on as soon as the power is
applied to the controller.
A wiring diagram for the glow plug control is shown in
Illustration 17.
Autocrank Wiring
The ECG offers an autocrank feature for the use on
remote starting or automatic starting. Contact your
Perkins dealer or your Perkins distributor for further
details.
Either of the two auxiliary outputs may be configured
for autocrank operation.
14
Installation of the Autocrank Wiring
g01344645
Illustration 18
Typical example of the wiring for the autocrank wiring
(1) Controller
(2) Autostart switch input

(4) Electric starting motor
Install the wiring to the autostart switch. Connect the

input for the controller on the ECG to (2) (switch to
vbat).
NOTICE
If using the autocrank feature, ensure that the
autocrank feature has been calibrated prior to
connecting to the ECG controller.
Install the wiring to the electric starting motor relay

on the engine. Connect the positive side of the coil
on the relay to the Vbatt+ connection. Connect the
negative side of the coil to either auxiliary output J2-3
or J2-4. This depends on the configuration of the
auxiliary outputs.
If the Electronic Controlled Governor (ECG) controller is not calibrated for the autocrank feature
and the crank motor relay is connected, the engine may start as soon as power is applied to the
controller. This could result in the possible loss of
engine control which could result in personal injury or death. Be sure to calibrate the autocrank
feature before you connect the ECG controller.
Note: If the auxiliary output draws more than 200

mA, the auxiliary output will be disabled and a fault
code will be activated.
Connect the power supply side of the relay switch to
the Vbatt+ connection. Connect the remaining side of
the relay switch to the solenoid of the electric starting
motor.
A wiring diagram for the autocrank is shown in

Illustration 18.
Once the input for the ECG is wired, the parameters

require calibration. Refer to this Special Instruction,
Perkins Electronic Controlled Governor, Calibrating
the Features of the ECG.
15
Auxiliary Output Wiring
g01303660
Illustration 19
Typical example of a wiring diagram for the lamp
(1) Controller
(2) Lamp
g01344672
Illustration 20
Typical example of a wiring diagram for the relay
(1) Controller
(2) Relay
(3) Input for auxiliary equipment
The ECG offers a feature for a lamp or a relay that

may be installed to either of the two auxiliary outputs
for a variety of purposes:
Indicates the overspeed condition
Flash faults
Autocrank output
Diagnostic shutdown
16
Glow plug relay control

Refer to OEM specifications for further information in
order to install the lamp or install the relay.
Note: If the auxiliary output draws more than 200
mA, the auxiliary output will be disabled and a fault
code will be activated.
A wiring diagram for the lamp is shown in Illustration
19.
A wiring diagram for the relay is shown in Illustration
20.
Engine Protection Input Wiring
g01303667
Illustration 21
Typical example of a wiring diagram for the engine protection
(1) Controller
(2) Oil pressure switch
17
g01303676
Illustration 22
Typical example of a wiring diagram for sensors that are wired in parallel
(1) Controller
(2) Oil pressure switch
(3) Coolant temperature switch
Hardware requirements
The controller for the ECG offers a feature for an

engine protection shutdown. The engine protection
shutdown protects against adverse operating
conditions such as low oil pressure or high coolant
temperature.
The following hardware is required in order to operate

the ECG software:
IBM-COMPATIBLE PC
The input for the engine protection is a switched input

that is similar to the set speed inputs. The input of the
switch must be to the ground potential.
CD-ROM drive
Serial port with a DB-9 connector that is capable of
A wiring diagram for the engine protection is shown

in Illustration 21.
9600 baud communication
Windows 2000/XP software
The sensors must be wired in parallel if more than

one sensor is used. A wiring diagram of the sensors
that are wired in parallel is shown in Illustration 22.
64 MB of available RAM memory and an hard disk

space of at least 2.0 MB of free disk space
SVGA video card and monitor. Capable of 256
Once the input for the engine protection is wired, the

parameters require calibration. Refer to this Special
Calibrating the Features of the ECG.
colors and 800 by 600 display.
Operation of the ECG Software

The ECG software is used in order to program the
ECG. The ECG software will monitor the controller
for the ECG.
18
Installation of the Hardware
g01343732
Illustration 23
Typical example of the hardware
(1) Controller
(2) OEM connection
(3) Harness
(4) PC
(5) RS-234 cable

(6) Interface module
Installation of the ECG Software
A nine pin RS-232 cable is used in order to connect

the ECG to the PC. A proprietary interface module is
required to connect the ECG to the communication
port on the PC.
The ECG software may be automatically installed

to the hard drive of a PC from the CD-ROM. The
CD-ROM is supplied with the ECG.
Use the following process in order to install the

hardware for the ECG.
Use the following process in order to install the ECG

software:
1. Ensure that the power supply to the ECG and the

power supply to the PC is isolated before making
connections.
Note: Close all applications in order to prevent

possible conflict between the software and other
programs.
2. Connect one end of the RS-232 cable to the

communication port on the PC. Connect the other
end of the RS-232 cable to the interface module.
1. Ensure that the power supply to the PC is switched

ON. Insert the software disk for the ECG into the
CD-ROM drive. Installation of the ECG software
should now begin. The ECG software may also
be installed by selecting the CD-ROM drive in
Windows Explorer.
3. Connect the interface module to the ECG by

using the connector on the harness. The interface
harness is inserted to the J1 (Gray) connector that
is located on the controller. The interface harness
is inserted to the J1 (Gray) connector of the OEM
harness.
2. Follow the prompts that are shown in the ECG

software for installing the ECG software . The
operator may select the default directory. The
operator may specify individual settings.
A diagram of the hardware is shown in Illustration 23.
3. When the installation is complete, the software for

the ECG may be accessed through the PC start
menu or by creating a shortcut.
19
4. The installation is now complete and the ECG

software is ready to use. For information on
operating the software for the ECG, refer to this
Governor, Basic Software Operation.
5. Remove the software disk for the ECG from the
CD-ROM drive.
Basic Software Operation

The following information will provide the operator
with a basic understanding in order to operate the
software for the ECG.
Operating the ECG Software
The ECG software is easy to use. The following
procedure will enable the operator to run the software
program for the ECG.
1. Ensure that the power to the controller for the
ECG is connected. Ensure that the controller is
connected to the PC communication port.
2. If an icon for the calibration tool exists, double click
on the icon in order to start the software. If no icon
exists, click on the start menu. Select programs
and select the software for the ECG. The default
setting is Perkins Engine. Select the ECG
Calibration Tool in order to start the program.
3. Ensure that the designation for the communication
port in the software for the ECG matches the
serial port on the PC. To change the assignment
for the communication port , follow the procedure
that is outlined in the Configure Menu. For
information on the Configure Menu, refer to this
Governor, Configure Menu.
20
Progress Display Screen
g01304901
Illustration 24
A typical view of the Progress Display Screen
The Progress Display Screen is designed to inform

the user of the progress of the communication
procedures. The Progress Display Screen will close
automatically when the procedure is complete.
Software Menus and Options
A typical view of the Progress Display Screen is

File Menu
The ECG software has five main menus. The five

main menus have the following available options:
Calibrate Menu
Navigating Around the ECG Software
Monitor Menu
There are five available main menu items in the ECG

software. Refer to this Special Instruction, Perkins
Electronic Controlled Governor, Software Menus and
Options for further information.
Configure Menu
Help Menu
The following procedures will assume that the cursor

is at the Main Menu screen. Use the following
commands in order to navigate around the Main
Menu screen:
File Menu
Use the mouse in order to select the menu. Use
Viewing files
The File menu allows the user to perform the

following operations:
the mouse in order to navigate around the menu.
Saving files
Use the left mouse button to execute a command
Converting files
or accept a condition.
Use the function key F1 for help.
A list of the commands are shown in Table 7.
A hot key (highlighted character in a main item)
can also be used to access a menu. A hot key

(highlighted character in a main item) can also be
used to access a submenu.
Click on the X box in the upper right hand corner

in order to exit software.
21
Table 7
Main Menu
Commands
Save ECG Cal to File
View Cal File Comments
View Text File
File Menu
Convert ECG Cal to Text

Convert Cal File to Text
Convert Cal File to
Strategy
Save ECG to Cal to File

This command allows the calibration data to be saved
to a designated file. This procedure is recommended
before any work is carried out on the ECG.
The ECG software uploads the calibration set
from the controller. The calibration set includes all
available parameters. The calibration set is saved to
a designated file. This operation is usually carried
out when the controller has been calibrated for
satisfactory engine performance. The operation may
also be carried out at any other time.
Note: The data is saved in a binary file that is not
able to be read.
Use the following process in order to operate the
Save ECG Cal to File procedure.
g01305276
Illustration 25
Typical view of the Select/Create File Name to save to window
22
1. Select the File option from the drop-down menu

in the ECG software. Select the Save ECG Cal
to File option. The software will prompt the path
in order to save the file. The Select/Create File
Name to save to window is displayed. A view of
the Select/Create File Name to save to window
is shown in Illustration 25.
2. Enter a name for the file in order to save the
calibration data. If a file extension has not been
specified, the software will automatically add the
file extension to the name of the file. Select the
Save option.
g01308630
Illustration 26
3. The ECG software will read all of the current

calibration values from the controller. Illustration
26 shows the progress of the current calibration
values that are being read.
Illustration 27
g01308657
23
g01318285
Illustration 28
4. The current calibration values from the controller

will be read by the ECG software. The ECG
software will prompt the operator to add comments
to the software file. The prompt for the software
is shown in Illustration 27. If the Yes option
is selected, the Cal File Comment List will
appear. The Cal File Comment List is shown
in Illustration 28. In order to enter comments,
type the comments one at a time and select the
Save Edit option. In order to edit the comments,
select the comment on the top line of the Cal File
Comment List and edit the comments. In order to
save the new comments, select the Save Edit
option. Comments can be deleted by selecting
the comment and selecting the Delete option.
Select the Cancel option in order to close the
window. The calibration file will still be created if
the comment editor screen is cancelled.
6. A message will be displayed when the file has

been created successfully. The name of the file
that is shown in the message is the name of the
file that was entered in Step 2. An example of the
message is shown in Illustration 29.
Note: The Save ECG Cal to File command stores
the calibration data as a software file. The software
file cannot be printed directly. The software file
cannot be viewed directly. Printing and viewing must
be done from a converted text file. Refer to this
Governor, Convert ECG Cal to Text and the Special
Convert Cal File to Text for further information.
View Cal File Comments
The View Cal File Comments option allows the
operator to display the Cal File Comments that are
attached to a calibration file.
5. Select the OK option on the comment editor

screen in order to save comments.
The Cal File Comments that have been created in

the calibration file assist in monitoring the following:
Engine data
Application data
Environmental data
Use the following process in order to view the
calibration Cal File Comments.
Illustration 29
g01315904
24
Convert Commands
The Save ECG Cal to File command stores the
calibration data as a software file. Printing and
viewing must be done from a converted text file.
The following commands are available with the ECG
software:

Convert Cal File to Strategy
The View Text File command may be used to view
the text file.
Illustration 30
The Convert ECG Cal to Text command allows the

operator to create a text file. The text file is created
by using calibration data for viewing or for printing
from any text editor utility in Windows software.
g01316575
1. Select the File option. Select the View Cal

File Comments option. The ECG software will
display a list of files at the top of the View Cal File
Comments window. The Cal File Comments
will be displayed on the lower half of the View
Cal File Comments window. The View Cal File
Comments window is shown in Illustration 30.
A printed copy of the calibration data may be useful

for future reference.
Use the following process in order to Convert ECG
Cal to Text.
1. Select the File option. Select the Convert ECG
Cal to Text option.
2. Select the desired Cal File in order to highlight

the Cal File. Use the UP and DOWN arrow keys
in order to navigate through the Cal File.
2. The ECG software will prompt the operator to

enter a name in order to save the text file. Select
a file and select the Save option.
3. Select the Cancel option in the View Cal File

Comments window in order to close the View
Cal File Comments window.

enter comments. Select the No Comments
option if no data is required. Enter comments and
select the Save Comments option in order to
save the comments.
Note: The comments are created or the comments

are edited when the files are created. Refer to this
Governor, Save ECG Cal to File for further
information.
The ECG software will read all of the calibration

values from the saved file. The ECG software will
create a text file in order to save the text file with the
parameter names, values and units.
View Text File

The View Text File allows the operator to view text.
Use the following process in order to View Text

Files.
The Convert Cal File to Text command allows the

operator to convert a previously saved calibration file
to a text file. The text file can be used for viewing
or printing using a text editor utility in the Windows
software.
1. Select the File option. Select the View Text File

option.
2. The ECG software will prompt the operator for a
text file to be viewed. Select a file and select the
Open option.
A printed copy of the calibration data may be useful

for future reference.
3. The ECG software will open the selected text file

with a default viewer.
Use the following process in order to Convert Cal

File to Text.
25
1. Select the File option. Select the Convert Cal

File to Text option.
2. Select the Cal File that requires converting.
Select the Open option.
the Save option.
enter comments. Select the No Comments
option if no data is required. Enter comments and
select the Save Comments option in order to
save the comments.
g01327519
Illustration 31
Convert Cal File to Strategy

values from the controller. The ECG software will
parameter names, values and units. A view of the
text file window is shown in Illustration 31.
The Convert Cal File to Strategy command is

used in order to convert old ACT files for use with
controllers that have a different control strategy
version. The software will carry out the following
procedures:
Analyze all of the calibration parameters in the old

software file.
26
Search for the same calibration parameters in the

new software file and assign values from the old
calibration file.
Use the following process in order to Convert Cal

File to Strategy.
1. Select the Cal File that requires conversion.
Select the Open option.
the Save option.
enter comments. Select the Save Comments
option. If no comments are required, select the
No Comments option.
values from the controller. The ECG software will
parameter names, values and units.
Illustration 32
g01317763
2. Select the Cal File that requires downloading. A

view of the Choose a Calibration file to download
window is shown in Illustration 32.
Calibrate Menu
The Calibrate Menu allows the operator to perform
operations that are related to the calibration of the
ECG. The following commands are available:
Download Cal File to ECG

Compare ECG Cal to File
Calibration Wizard
Download Cal File to ECG
The Download Cal File to ECG command allows
the operator to download the entire calibration set
from a file to the permanent memory of the ECG.
Illustration 33
g01317782
Illustration 34
g01317792
This command can be used for the following:
Reverting to a known good calibration set after

experimenting with new calibration settings
Programming multiple units for a particular

application
Program the ECG with the default calibration

settings.
The downloaded file may have been previously

configured and calibrated for satisfactory engine
performance with another engine.
Use the following process in order to Download Cal
File to ECG.
3. Select the Open option. Illustration 33 shows the

progress of the current Cal File downloading.
Illustration 34 is displayed when the download is
completed.
1. Select the Calibrate option. Select the Download

Cal File to ECG option.
27
Compare ECG Cal to File

The Compare ECG Cal to File command allows the
operator to check the differences in calibration sets
between a saved file and the calibration of the ECG.
This feature is useful to ensure that the saved file
matches the calibration in the calibration of the ECG.
Use the following process in order to Compare ECG
Cal to File.
Illustration 35
Illustration 37
g01318067
Illustration 38
g01318066
g01318054
1. Select the Calibrate option. Select the Compare

ECG Cal to File option. Illustration 35 shows the
Choose a Calibration file to compare window.
3. The Compare Difference window will be

displayed when the file is downloaded. The
message displays a list that shows the Compare
Results. An example of the Compare Difference
window is shown in Illustration 37.
Note: If the parameters in the file match the
calibration of the ECG, a message will be displayed
showing that all files match. Select the OK option
in order to close the window. An example of this
message is shown in Illustration 38.
Illustration 36
4. If mismatches are shown, select the Save to

File option. The Save to File option is shown in
Illustration 37.
g01318056
2. Select the calibration file that requires comparing.

Select the Open option. Illustration 36 shows
the progress of the current calibration file
downloading.
28
Calibration Wizard
The Calibration Wizard command allows the
operator to use an interactive guide in order to
calibrate the ECG for specific engine requirements.
Use the following process in order to calibrate the
ECG by using the Calibration Wizard.
1. Select the Calibrate option. Select the
Calibration Wizard option.
Illustration 39
g01318167
Illustration 41
g01319278
2. Select the appropriate Base Engine Calibration

File (CFG file). Select the Open option.
Illustration 41 shows the Select a Base Engine
Calibration File window.
Illustration 40
g01318124
5. The Select/Create File Name to log to window

is displayed. Select an existing text file. If a
text file does not exist, create a text file. The
Select/Create File Name to log to window is
shown in Illustration 39. Select the Save option
in order to save the mismatched files. The report
will be written to the text file and the file may be
opened in order to review the data. An example of
the text file is shown in Illustration 40.
6. Select the File option. Select the Print option in
order to print the document. In order to close the
window, select the File option. Select the Exit
option.
29
g01319311
Illustration 42
Note: Select the Cancel option in order to abort the

Calibration Wizard.
3. The Calibration Wizard will prompt the operator

to start the Calibration Wizard with one of the
following options:
Start with default values

Start with current values.
Illustration 42 shows the prompt message of the
Calibration Wizard window.
4. Select the option that is required. The options are
shown in step 3.
Illustration 43
g01319340
5. Select the Next option in order to download the

selected values. Illustration 43 shows the progress
of the selected values that are being downloaded.
30
g01319347
Illustration 44
6. The Calibration Wizard will guide the operator

through the process for calibration by using a
series of questions. The Calibration Wizard will
prompt the operator to confirm that the values are
correct. The Calibration Wizard window is shown
in Illustration 44.
7. Select the Next option in order to confirm and

download the selected values. The selected
values will download the new calibration to the
ECG. The new calibration values will reset all of
the parameters in the ECG. Illustration 45 shows
the progress of the selected values that are being
downloaded.
Note: Select the Cancel option in order to abort the
Calibration Wizard.
8. The Calibration Wizard process is now complete.
A window will be displayed in order to give the
user the following options:
Show Engine Speed Graph

Save ECG Configuration to a File
Illustration 45
Note: The engine may be fine tuned by adjusting

the PID gains. The PID gains are contained in
the Parameter Plot Screen. Refer to this Special
Monitor Menu for further information.
g01319364
31
Note: The Calibration Wizard only covers basic

calibration. The Calibration Wizard does not
automatically assume optimum engine operation.
The engine should be operated to an acceptable
standard by using the default parameters. Refer
to this Special Instruction, Perkins Electronic
Controlled Governor, Calibrating the Features of the
ECG for further information.
Monitor Menu
The Monitor Menu allows the operator to observe
the engine and operation of the ECG in real time.
The following commands are available:
Parameter View
Parameter Plot
Display Faults
Control Strategy
Parameter List
Parameter View
The Parameter View command allows the operator
to view certain operating variables in real time.
Use the following process in order to view operating
variables by using the Parameter View.
1. Select the Monitor option. Select the Parameter
View option.
32
g01320167
Illustration 46
2. The Parameter View window is displayed.

The Parameter View window automatically
starts to read the values from the controller. The
Parameter View window automatically displays
the values. The Parameter View window is
3. Select the Stop option in order to stop reading
the values and displaying the values. The Stop
option will automatically change to a Start option.
Selecting the Start option will begin to read the
values. Selecting the Start option will display
the values.
Note: The Parameter View command will
automatically close if any other feature that
communicates with the controller is used.
Parameter Plot
The Parameter Plot command allows the operator
to view engine performance on a display in the form
of a real time graph. This feature allows the operator
to view the system in order to observe the response
to fine tune engine performance.
Use the following process in order to view engine
performance by using the Parameter Plot command.
Plot option.
33
g01320203
Illustration 47
Make PID Gain Adjustment from the Plot

Display window
2. The Parameter Plot window is displayed. The

Parameter Plot window automatically starts to
read the previously saved configuration. The
controller requests the parameter values. The
Parameter Plot window is shown in Illustration
47.
Use the following process in order to Make PID Gain

Adjustment from the Plot Display window.
1. In order to make adjustments in the appropriate
field, select one of the fields for the PID gain
adjustment. A description of the fields for the PID
gain adjustment are shown in Table 8.
The controller transfers the data to a PC. The data

may be transfered at various speeds. The transfer
of the data depends on the number of parameters
that are being monitored. The application uses the
Windows software in order to update the screen at
the specified rate.
Note: The display screen and the data files may only
be used as reference.
The resolution of the monitor can affect the X axis
time scale that is displayed. This value will be
adjusted when the graph is resized. This also applies
to the print function for this window.
All of the data will be recorded in a revolving buffer
for use in the Save to File feature.
The axis scales, parameter names, update resolution
and time scale on the Parameter Plot may be
changed. Refer to this Special Instruction, Perkins
Electronic Controlled Governor, Change Plot Setup
34
Table 8
Description
Code
P
Proportional gain
Integral gain
Derivative gain
2. New gain adjustment values may be typed into

the field directly.
3. Select the Enter key in order to save the new
value in the ECG.
4. Select the Escape key in order to cancel the gain
adjustment field.
Change Plot Setup
The Change Plot Setup option allows the operator
to choose engine rpm, desired engine speed, the
duty cycle or any other parameters for viewing or real
time plots on the screen. Axis scales may also be
adjusted in order to fit the parameter or the speed.
Use the following process in order to Change Plot
Setup.
1. Select the Configure option from the Parameter
Plot window. Refer to this Special Instruction,
Perkins Electronic Controlled Governor,
Parameter Plot for further information. The
Parameter Plot window is shown in Illustration
47.
2. Use the pull-down menu in order to select the
desired plot. The Change Plot Setup will display
the following fields. The fields are shown in Table
9.
Table 9
Plot
Description
Plot1/Plot 2
Use the pull-down menu within Plot1/Plot 2 in order to select

the desired parameter.
Axis Min/Max
Enter the minimum/maximum value for the parameter value
X Axis time scale
Controls the amount of data that is displayed on the X axis.

This value may automatically adjust the screen resolution
X Axis sample rate
Manage data that is used to update the screen. Data that is

received between the timer ticks is discarded.
Display Faults
3. Select the OK option in order to save the data

in the Windows registry. The information will be
stored when the program is restarted.
The Display Faults option allows the operator

to view the faults in real time. New faults will
automatically be displayed.
Note: The Calibration Wizard will automatically set

up the plots if there are no saved defaults.
Use the following process in order to display the

faults in real time.
35
g01320632
Illustration 48
To clear historical faults, select the Clear Historical

Faults option in the Diagnostic View window.
1. Select the Monitor option. The application

will display the Diagnostic View window. The
Diagnostic View window is shown in Illustration
48. The Diagnostic View window will be updated
when the controller sends the fault flags status.
Control Strategy
The Control Strategy option allows the operator
to check the version of the control strategy that is
being used. This information may be required for
identification of the strategy and for future use.
2. Select the Pause option in order to stop

automatic updates of the screen. The Pause
option will automatically change to a Start
option. Selecting the Start option will restart the
automatic updating of the faults.
Parameter List
Note: The Display Faults option will automatically

pause if any other feature that communicates with
the controller is used.
The Parameter List option allows the operator

to adjust the parameters that are displayed in the
Parameter List window.
The controller has the ability to recall faults that have

been cleared. The controller has the ability to recall
faults that have occurred in the past. The controller
stores each fault in a non-volatile memory. Historical
faults will appear in the lower half of the Diagnostic
View window.
Use the following process in order to display the

Parameter List.
The historical faults are read and displayed upon

opening the Diagnostic View window. After opening
the Diagnostic View window, the current faults are
updated in real time. In order to update historical
faults, select the Update Historical Faults option in
the Diagnostic View window. This would be useful
for checking if a current fault had been generated and
the fault had been cleared without noticing the fault.
36
g01320735
Illustration 49

List option. The Parameter List window is shown
in Illustration 49.
2. Select the F5/F6 keys on the PC keyboard in
order to navigate through the parameters on the
Parameter List window.
3. Select the F9 key in order to switch ON the
parameter in the Parameter View window. Refer
Controlled Governor, Parameter View for further
information.
4. Select the F9 key in order to switch OFF the
parameter in the Parameter View window. Refer
Controlled Governor, Parameter View for further
information.
Use the following procedure in order to close the
Parameter List:
Illustration 50
1. In order to close the Parameter List window,

select the X in the top right hand side of the title
bar.
g01343998
2. Selecting the Save option will prompt the

operator to enter a name in the File name field.
Illustration 50 shows the Choose a file name to
save the view setup to window. Type in a name
in the File name field that reflects the purpose of
the saved configuration. Select the Save option.
Use the following process in order to open the

Parameter List window:
1. The Parameter List window must be closed and
reopened if any changes are made in order to
make changes effective.
Use the following procedure in order to open a

previously saved View Configuration:
37
1. Select the desired file in the Choose a file name

to save the view setup to window.
2. Select the Open option.
3. The View Configuration will be updated with the
saved parameters.
The ECG application will always recall the default set
of plot configuration parameters at the start-up of the
application. The ECG application does not recall the
last used view set up file. The View Configuration
will always start with the default view.
Several Parameter View windows can be opened
with different configurations. The Parameter View
windows are opened by changing the configuration
on the Parameter List window. A new Parameter
View window can then be opened.
Note: Only one of the Parameter View windows can
be monitoring the controller at any time.
Configure Menu
The Configure Menu option allows the operator to
designate the correct communication port for the
PC in order to enable communications between the
actuator and the controller. The Configure Menu
option allows the operator to start a Demonstration
Mode for various supported controllers.
Configure the Serial Port
Use the following process in order to configure the
serial port.
1. Select the Configure option. Select Com 1 or
Com 2 in order to attempt to open the serial port
and establish communication with the controller.
Configure the Demonstration Mode
Use the following process in order to configure the
Demonstration Mode.
1. Select the Configure option. Select ECG 4500
DEMO option. The application will simulate
communications with the controller.
38
Configure a Custom Serial Port
g01320819
Illustration 51
Use the Help Topics option in order to search for

specific information.
Use the following process in order to configure a

custom serial port.
1. Select the Configure option. Select the Custom
Serial Port option. The application will display the
ACT Communications Configuration window.
The ACT Communications Configuration window
is shown in Illustration 51.
2. Select the Custom option. Enter the required
communications port into the Custom Field.
Note: Upon inputting data into the field for the
Custom Com port, no space should be included in
the text. A typical example is shown in Illustration 51.
3. Select the OK option in order to save the
selected Custom communications port.
Help Menu
The Help Menu option provides the operator with
on-line access to the user manual and other helpful
information. The following commands are available
from the Help Menu option.
Help Topics
About ACT
User Manuals
Help Topics
The Help Topics option allows the operator to
search for specific information by displaying menu
items or by searching using words or by using a
phrase.
39
g01321201
Illustration 52
Compact disc
1. Select the Help option. Select the Help Topics

option. The Help Topics window is displayed. The
Help Topics window is shown in Illustration 52.
The Contents option will provide an outline of the
software applications. The software applications
are listed by menu items. The Index option will
enable the operator to locate a specific topic by
using an alphabetical listing. The Index option
will enable the operator to locate a specific topic
by typing a word or phrase into the search field.
The search field is located at the top of the Help
Topics window.
Perkins Service and Parts Information (SPI)

Perkins Manual
Calibrating the Features of the ECG
If the operator does not have any specific
requirements for calibration, choose the Download
Cal File to ECG option. Refer to this Special
Download Cal File to ECG for further information.
2. The Help Topics option will prompt the operator

with a series of questions in order to navigate
through the manual.
The Calibration Guide

This section explains the procedures for calibrating
the various features of the ECG in order to work with
the application.
About ACT
The About ACT option displays the version of the
calibration tool that is being used. This information
is important for tool identification and for servicing
support.
Note: Before proceeding, ensure that the operator

has completed the installation of all required
hardware for the system. Ensure that the operator is
trained in using the ECG.
User Manual
The user manual contains comprehensive information
on the controller, wiring diagrams, menus and
calibration parameters. The user manual can be
accessed through the following:
On-line facility
40
NOTICE
It is possible to enter values in the ECG controller
that are in excess of what the engine is capable of
performing and outside the engine operating range.
It is the users responsibility to be accurate when
entering data into the ECG or the software. Entering
values outside the safe operating range can result in
damage to the equipment or application.
An engine overspeed device, independent of the

electronic controlled governor (ECG), must be
provided to prevent loss of engine control that
may result in personnel injury or death.
Calibration Categories
The calibration categories allow the user to
incorporate any of the programmable features in
the system. The parameters for the programmable
features must be calibrated. The ECG software
will calibrate each of the features in the ECG. The
parameters are grouped under various categories
within the Calibration option. Refer to this Special
Calibrate Menu for further information.
A list of calibration categories and calibration features
are shown in Table 10.
Table 10
Calibration Category
Features
Governor Gain
PID gain settings
Engine set speed
External potentiometer calibration
Engine start
Autocrank, glow plugs
Diagnostics
Overspeed/underspeed protection
Actuator output
Auxiliary output
Note: There is no requirement for the configuration

of any parameters in order to start basic operation of
the ECG. All parameters are preset to values that will
work with many applications.
2. If no icon exists, select the Start option on

the PC. Select the Programs option. Select
the Perkins Engine option. Select the ECG
Calibration Tool option.
Calibrating the Controller
3. Ensure that the communication port designation

in the ECG software matches the serial port on
the PC. The Configure Menu will be displayed.
If the communication port assignment requires
changing refer to this Special Instruction, Perkins
Electronic Controlled Governor, Configure Menu
Ensure that the controller is connected to the

communication port. Ensure that the controller is
powered up.
Use the following process in order to calibrate the
controller.
1. If an icon exists for the calibration tool, double
click the icon in order to start the software.
41
The ECG software restricts the operator from

entering values outside the specified range. The
values outside the specified range are entered. A
warning will be displayed. A list of available ECG
calibration parameters are shown in Table 11.
The Calibration Wizard may be used for specific

calibration. The Calibration Wizard is an interactive
guide that is used in order to help in setting up the
controller to specific requirements. Refer to this
Governor, Calibration Wizard for further information.
NOTICE
The range is fairly wide and it is possible to enter
values in excess of the capability of the application.
The range is limited for engine protection and human
safety. The limits do not reflect the capability of
any application that may be driven. It is possible
to command engine speeds up to 2500rpm with
the ECG software. The engine may not be able to
operate at this speed due to mechanical limitations.
All calibration settings are automatically saved in

the controller. The calibration settings remain in the
memory after shutdown. Saving may be helpful in
case of failure of the controller or for calibrating in a
similar application at a later date.
Saving a Calibration Set to a File
After achieving satisfactory engine performance, the
calibration set must be saved.
A saved file allows the operator to experiment with
other calibration settings. The operator will be able
to recall the saved calibration set.
A saved calibration set can be used for configuring
additional units.
In order to save a calibration set to a file, refer
Controlled Governor, Save ECG Cal to File for
further information.
Calibrating the Controller with a Saved Calibration
File
Several units may be calibrated with a saved
calibration file for consistent, optimized operation.
In order to calibrate the controller with a saved
Calibration File, refer to this Special Instruction,
Perkins Electronic Controlled Governor, Download
Cal File to ECG for further information.
Note: Ensure that the controller is powered up. The
controller does not need to be mounted to the engine
in order to carry out the calibration procedure.
Understanding the Calibration

Parameters of the ECG
The calibration parameter is a numerical value that
assists the operator in adjusting the controller or
setting the controller. Once the controller is calibrated,
the parameter is not subject to any changes while the
system is operating. The calibration parameters for
the ECG are used to configure the ECG for different
applications.
ECG is a programmable system that requires no
manual adjustment. Calibrating is the only means
of configuring and adjusting the controller for the
specific application.
42
Table 11
Parameter
Category
Governor Gain Calibration
Speed input configuration
Engine start calibration
Diagnostic calibration
Actuator output calibration
Description
Proportional gain
Transient response
Integral gain
Steady state speed stability
Derivative gain
Speed stability
Ramp down rate
Engine speed ramp down rate
Ramp up rate
Engine speed ramp up rate
Set speed 1
Engine set speed 1
Set speed 2
Engine set speed 2
Set speed 3
Engine set speed 3
Set speed 4
Engine set speed 4
Set speed warm up
Engine warm up speed
Warm_up_time
The time that is spent at warm up speed
Speed_type
Magnetic pickup
Autocrank crank time
Starting motor solenoid time (seconds)
Autocrank max tries
Number of autocrank attempts
Autocrank rest time
Rest time between autocrank attempts

(Seconds)
Glow plug time
Glow plug time (seconds)
Overspeed_rpm
Actuator shutdown speed (Maximum)
Underspeed_rpm
Actuator shutdown speed (Minimum)
Aux_Output_rpm
Drive auxiliary output when engine speed

is above this rpm
Aux_Output_2 rpm
If the engine speed exceeds this value the

auxiliary output 2 will engage
Droop_Percent
Percentage Droop
Configuration Modes for the Switch

The switch inputs and the parameters for the speed
setpoint are used in order to set up the four discrete
speeds. The switch inputs and the parameters for
the speed setpoint are used to set the ramp up rates
between speeds. Refer to this Special Instruction,
Perkins Electronic Controlled Governor, Switch
Wiring for further information. The configuration
modes for the switch are shown in Table 12.
43
Table 12
Configuration Mode
Description
= 1: Single speed
A single engine speed is commanded.

The engine is started. The engine moves from the cranking
mode to the run mode. The engine speed will increase from
SET_SPEED_WARMUP at the RAMP_UP_RATE.
Engine speed remains at the warm up speed for
the WARMUP_TIME (seconds). The engine speed
either increases at RAMP_UP_RATE or decreases at
RAMP_DOWN_RATE to SET_SPEED_1
= 2: Two speed
A switch is used in order to select two set speeds.

mode to the run mode. The engine speed will increase from
SET_SPEED_MIN to SET_SPEED_WARMUP at the
RAMP_UP_RATE.
WARMUP_TIME seconds. The engine speed
increases at RAMP_UP_RATE or decreases at the
RAMP_DOWN_RATE. The speed is selected by the switch
(SET_SPEED_1 or SET_SPEED 2). The other speeds
are selected with the switch. The engine speed is ramped
to the new set speed.
= 3: Three-speed
The switch can choose up to three different set speeds.

mode to run mode. The engine speed will increase from
RAMP_UP_RATE.
Engine speed remains at the WARMUP_TIME seconds.
The engine speed increases at RAMP_UP_RATE or
decreases at RAMP_DOWN_RATE. The speed is selected
by the switch (SET_SPEED_1 to SET_SPEED_3). The
other speeds are selected with the switch. The engine speed
is ramped to the new set speed.
= 4: Four speed
A switch with two diodes is used. The switch will select four
set speeds.
The engine is started. The engine moves from cranking
mode to run mode. The engine speed will increase from
RAMP_UP RATE.
WARM_UP_TIME seconds. The user may select a new
speed by using the switches. The switch will increase the
engine. The switch will decrease the engine speed.
A brief pressing of the switch will change engine speed
by one rpm. Closing the switch for a longer period will
ramp the engine speed. The engine speed will first be
ramped at a slow rate. The engine speed will then increase
at the RAMP_UP_RATE. The engine will decrease
at the RAMP_DOWN_RATE. This depends on the
switch position. The engine speed will never ramp above
SET_SPEED_MAX or below SET_SPEED_MIN.
44
Engine Start Calibration Parameters

Glow Plug Control
If the Calibration Wizard option is used, the auxiliary
output can be configured to turn on the glow plug
relay before engaging the Autocrank relay upon
receiving a command from the auto-start switch.
The glow plug relay will remain on until the engine
starts or until the Autocrank sequence completes
the maximum permissible number of crank cycles.
This feature is useful for remote operation of certain
engines or applications. Refer to this Special
Calibration Wizard for further information. The
calibration parameters that require a configuration
Table 13
Parameter
Description
AUXILIARY_OUTPUT_MODE
The parameter is used in order to allow the ECG software to

identify the auxiliary output that requires the configuration. (1)
AUXILIARY_OUTPUT_2_MODE
The parameter is used in order to allow the ECG software to

identify theauxilairy output 2 that requires the configuration.
(1)
GLOWPLUG_TIME
(1)
(1)
(2)
The parameter is used to specify the preheat time, in

seconds, before the Autocrank relay is engaged. (2)
Refer to this Special Instruction, Perkins Electronic Controlled Governor, Auxiliary outputs for further information.
Refer to this Special Instruction, Perkins Electronic Controlled Governor, Auxiliary outputs for further information.
Refer to the appropriate Operation and Maintenance Manual, Starting the Engine for further information.
The glow plug is enabled with the Calibration Wizard

by selecting the AUXILIARY_OUTPUT_MODE or
AUXILIARY_OUTPUT_2_MODE.
When the auto-start switch is made, the output of the
glow plug becomes active for GLOWPLUG_TIME
(sec) before the Autocrank relay is engaged.
Autocrank
On a command from an auto-start switch (using
J2-6), an engine will go through an autocrank
sequence with the use of the auxiliary output. This
feature is useful for remote operation of certain
engines or applications. The calibration parameters
that require a configuration are shown in Table 14.
45
Table 14
Parameter
Description
AUTOCRANK_CRANK_TIME
This value determines the amount of time that cranking will occur. If
the engine starts during the cranking period, engine cranking will
be terminated.
The range is between 0-31.9 seconds. (2)
AUTOCRANK_MAX_TRIES
The maximum number of crank cycles or the rest cycles before the
autocrank logic stops trying to start the engine. This will then flag
a fault.
The range is between 0-255 seconds. (2)
AUTOCRANK_REST_TIME
If the engine does not start during the cranking interval, cranking will
be disabled for AUTOCRANK_REST_TIME seconds in order to
permit the starting motor to cool.
The range is between 0-31.9 seconds. (2)
(2)
(2)
(2)
The Autocrank feature is enabled by

selecting the Calibration Wizard and
selecting the AUXILIARY_OUTPUT_MODE
or AUXILIARY_OUTPUT_MODE_2_MODE to 4.
If the auto-start switch is made, the autocrank output
waits for the GLOWPLUG_TIME (seconds). This
becomes active for AUTOCRANK_CRANK_TIME
(seconds) or until the engine starts. After an
unsuccessful attempt at starting the engine and the
output becomes inactive, another attempt is made in
order to start the engine. The sequence is repeated
for AUTOCRANK_MAX_TRIES. If the engine has
not started after the maximum attempts at cranking,
a fault is logged.
If the auto-start switch is turned OFF, the duty cycle
of the actuator is set to zero in order to shut down
the engine.
Diagnostic Calibration Parameters

Engine Protection Input
The selectable input protects against adverse
conditions such as high coolant temperature or low oil
pressure. In case of low oil pressure, the selectable
input allows the pressure of the engine to rise on
the start-up of the engine. Refer to this Special
Calibartion Wizard for further information . The
calibration parameters that require a configuration
46
Table 15
Parameter
Description
OVERSPEED_RPM
Critical engine speed is used for overspeed protection (rpm).

The OVERSPEED_RPM should be left at the default
setting if overspeed protection is not desired. Normal closed
loop governing will decrease the duty cycle to the actuator.
The duty cycle is closed when the engine speed is above
the set point. Overspeed protection immediately shuts off
the actuator when overspeed condition is detected. Engine
speed must be brought back to zero before the actuator is
driven again.
UNDERSPEED_RPM
This is the minimum engine speed required in order to

operate the underspeed shutdown function (rpm). If the
engine speed is to go below the set point the closed loop
governing system will increase the duty cycle of the actuator.
The function for the underspeed shutdown immediately shuts
the actuator at any time when the underspeed condition is
detected. Engine speed must be brought back to zero before
the actuator is driven again.
If an engine underspeed or an engine overspeed

condition is detected, the engine protection control
logic will cause the duty cycle of the actuator to go
to zero.
When an engine underspeed or an engine overspeed
condition is detected, the engine protection control
logic activates a fault code, which is signified with a
flashing LED. If the engine protection control logic
has tripped, the fault code will continue to flash the
LED. This informs the operator that the engine has
stopped. The engine stopping is due to the overspeed
of the engine or underspeed of the engine. The
engine may later be restarted without resetting the
unit. This action will cause the fault code to reset and
the LED will then stop flashing.
Actuator Calibration Parameters

Auxiliary Outputs
The two auxiliary outputs are multipurpose outputs.
The auxiliary output can drive a lamp. The auxiliary
outputs can drive a relay. Refer to this Special
Glow Plug Control Wiring for further information.
Controlled Governor, Autocrank Wiring for further
information. Refer to this Special Instruction,
Perkins Electronic Controlled Governor, Auxiliary
Output Wiring for further information. The calibration
parameters that require a configuration are shown
in Table 16.
47
Table 16
Parameter
Description
AUX_OUTPUT_RPM
The AUX_OUTPUT_RPM is selected by using the

Calibration Wizard. The ECG will switch the auxiliary output
ON. The auxiliary output switches ON if the engine rpm
exceeds this speed. If the engine speed decreases 20 rpm
below the AUX_OUTPUT_RPM the auxiliary output will
switch OFF.
AUX_OUTPUT_2_RPM
The AUX_OUTPUT_2_RPM is selected by using the

Calibration Wizard. The ECG will switch the auxiliary output
2 ON. The auxiliary output switches ON if the engine rpm
exceeds this speed. If the engine speed decreases 20 rpm
below the AUX_OUTPUT_2_RPM the auxiliary output will
switch OFF.
AUX_OUTPUT_MODE
This parameter determines the auxiliary output in order to

be configured.
AUX_OUTPUT_2_MODE
This parameter determines the auxiliary output in order to

be configured.
Governor Gain Calibration Parameters
The Calibration Wizard can be used in

order to select the following options:set
the AUXILIARY_OUTPUT_MODE and the
AUXILIARY_OUTPUT_2_MODE values to the
settings that can achieve target configuration for a
certain ECG or the engine system. The following
settings can achieve the target configuration:
PID Gain Settings Response Plots
No auxiliary output
Output on when the rpm is more than
AUX_OUTPUT_RPM
Output on when the rpm is more than

AUX_OUTPUT_2_RPM
Output on when a fault exists

Autocrank mode
Illustration 53
Typical example of the PID gains too low
Simulates the on board ECM LCD
(Desired rpm) 1
(Actual rpm) 2
(Time) X
(rpm) Y
Glow plug control

Droop Governing
The droop can be used in order to assist in
stabilizing the engine. The percentage value that is
entered into the droop setting will be added to the
engine set speed. As load is added to the engine
the engine speed will drop accordingly. Droop
may be preferable in certain applications when
sharing of load occurs. When droop is set to zero,
governed speed will not be sensitive to load. The
DROOP_PERCENT parameter requires calibration.
The DROOP_PERCENT range is 0-8%.
Troubleshooting
The following section may be used in order to
troubleshoot the ECG.
48
g01345541
Illustration 54
g01345551
Typical example of the PID gains too high
Typical example of the integral gains too high or derivative gains

too low
(Desired rpm) 1
(Actual rpm) 2
(Time) X
(rpm) Y
Illustration 55
g01345760
Illustration 57
(Desired rpm) 1
(Actual rpm) 2
(Time) X
(rpm) Y
g01345556
g01324068
Illustration 58
Typical example of the integral gains too low
Typical view of a preferable response
(Desired rpm) 1
(Actual rpm) 2
(Time) X
(rpm) Y
(1) Remove the engine load

(2) Add to the engine.
(X) Time
(Y) rpm
The ECG software allows the operator to adjust the

proportional settings, integral settings and derivative
gain settings in order to observe the response directly
on the display screen in the form of a real time plot.
Troubleshooting Guidelines
Table 17
Required Tools
Illustration 56
Tool
Part Number
Part Description
Digital Multimeter
Qty
1
g01345569
Use Tooling A to measure the frequency and the duty

cycle.
Typical example of the derivative gains too high

(Actual rpm) 1
(Desired rpm) 2
(Time) X
(rpm) Y
Use the following procedure in order to troubleshoot

the controller.
49
1. Check the battery voltage for stability and the

correct value. The LED will switch ON for 1 second
when the ECG is first powered up.
2. For magnetic pickups, Use Tooling (A) in order to
check that the speed signal is at least 2 volts RMS.
The actuator should move to full travel during
cranking of the engine. The LED will illuminate
when engine speed is detected.
3. Confirm that the load is not inducing instability.
4. Adjust the gains in order to achieve engine
stability.
Fault Codes
Table 18
Flash Code
Fault
Engine Shutdown
Corrective Action
ECG unit not calibrated
Yes
Calibrate ECG unit
Engine speed excessive
Yes
Check Parameter settings.

Overspeed criteria may be
too sensitive
Check for electrical noise
entering controller
Check the wiring and
connections
Check the case to earth
Check the tip of speed
sensor
Engine speed unusually low
YES
Check the parameter

settings
Ensure that load is not
greater than engine
capacity
Engine shutdown due to engine

protection input
Yes
Check the parameter

settings
Check the fault that
may have triggered the
protection input
Factory settings have been lost
Yes
If the calibration file

is available, download
calibration file and cycle
power again
If the controller still does not
function correctly or if no
calibration file is available,
contact your Perkins dealer
or your Perkins distributor
for assistance.
The controller unit failed
Yes
Electrical noise may be

entering the controller.
Check the wiring, shielding
and connections to the
controller
Cycle the power to the
engine
If the controller does not
function correctly, contact
your Perkins dealer or
your Perkins distributor for
assistance
(continued)
50
(Table 18, contd)
Limiting excessive actuator

current
No
Check the actuator for a

short to ground
Check the parameter
settings
Ensure that the load is
not greater than engine
capacity
10
The input for the engine speed

signal is missing.
No
(Only active in Autocran

mode)
Check the speed sensor
wiring
Check the starter motor
11
Autocrank is unable to start the

engine
No
Check the engine for

mechanical faults
12
Auxiliary output is shorted
No
Check that the lamp is

hooked to the output. Check
that the relay is hooked to
the output
If the fault is still present
for assistance
13
Auxiliary output 2 is shorted
No
Check that the lamp is

hooked to the output. Check
that the relay is hooked to
the output
If the fault is still present,
for assistance
14
The actuator might be

disconnected. The cctuator
has an open circuit
No
Check the actuator wiring

and actuator resistance
Resistance should be less
than 10 ohms
4. The controller will attempt to shut down for some

faults. The controller will not permit starting after a
reset when faults 1, 5 and 8 occur.
The controller is capable of identifying certain fault

conditions and alerting the operator of the fault
conditions. A flashing LED indicates a fault condition.
The list of faults is shown in Table 18.
Flow Chart for the Calibration Setup and

Configuration Parameters
The following procedures should be noted:

1. When power is first applied to the controller, the
LED will flash once for one second in order to
indicate that the LED is functioning correctly.
2. If there are multiple faults, the LED will flash
the faults in a sequence. Count the flash codes
in order to determine the fault conditions. The
calibration tool may be connected in order to
observe the fault conditions. Refer to this Special
Instruction, Perkins Electronic Controlled
Governor, Monitor Menu, Display Faults for
further information.
3. If no faults are found, the LED will flash once at
the reset. The LED will then indicate the detection
of the engine speed. A continuous illuminated
LED indicates that a valid engine speed is being
sensed.
51
g01334861
Illustration 59
52
g01345954
Illustration 60
53
g01345960
Illustration 61
54
g01335220
Illustration 62
55
g01335359
Illustration 63
56
g01335371
Illustration 64
57
Glossary of Terms
A glossary of terms is shown in Table 19.
Table 19
Term
Description
ACT
PC software program for configuring and calibrating the controller
Actuator
Device that converts an electrical signal from the controller to the

output shaft
Analog pedal position (APP)
An analog input with voltage that is proportional to the desired

engine speed
Autocrank
A feature of the ECG that allows remote starting of the engine by

using one of the auxiliary outputs. A feature of the ECG that allows
automatic starting of the engine by using one of the auxiliary outputs
Cal File
File that contains the details of the calibration
Cal tool version
The version of the software for the calibration tool that is used
Calibration
Process of configuring and adjusting the controller to work with a

specific application
Calibration Wizard
An interactive guide for the software that is used in order to help

the operator set up basic calibration in order to get the controller
in operation quickly
Control Strategy
The version of the software that resides in the ECG software
Duty cycle
The amount of time the pulse width modulated (PWM) signal is

in the ON position
Glow plugs
The electric heating elements that are used in order to enhance

cold starting of diesel engines.
The auxiliary outputs can be configured to control the glow plugs
through the relay
Parameter
Numerical value that helps the user calibrate the controller
PTO
Power take-off
The feature of the ECG that allows selection between pedal input
and speed switches
PWM
Pulse width modulation.

A means of simulating the analog output with a digital device
The PWM duty cycle determines the equivalent analog output: The
higher the duty cycle, the higher the equivalent analog output
Speed sensor
device such as a magnetic pickup that senses engine speed
58
59
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KENR6237

Perkins Electronic Controlled

400 Series Industrial Engines

An engine overspeed device, independent of the

The controller for the ECG is an electronic engine

The electronic controlled governor (ECG) provides a

Understanding the System

The controller for the ECG is programmed by the

The output of the controller is a pulse width modulated

Components of the Electronic

The actuator is mounted on the engine in place of

A typical view of the speed sensors

The ECG monitors the engine speed continuously.

A typical view of the actuator

Typical view of the ECG software

The actuator converts the pulse width modulated

The ECG software is designed to monitor the

Actuator current protection

Protects the actuator from burning out

For remote operation of engines when using an auxiliary output

Two outputs that can be configured to drive lamps or relays

Allows for speed governing that is not isochronous

Engine protection input

Protects against adverse conditions such as engine oil pressure or

Engine start calibration

For engines that require special start-up operation such as warm

Glow plug control

For enhancing cold start capability by using an auxiliary output

Allows the governor response to be adjusted by the operator

Switched speed setpoint

Allows for multiple speed settings by using switches

Universal speed inputs

Speed input is compatible with magnetic pickup(1)

Selection Options for Engine Speed

The ECG expands the Perkins line of programmable

The selection options for engine speeds that are

The ECG has an advanced input capability and an

Selection Options for

The programmable features that are available with

Use a speed switch in

The ECG software must be correctly installed in

Use a speed potentiometer

Installing the Hardware

Note: The hardware that is required for the

In order to install the main components, refer to the

Special Instruction, Perkins Electronic Controlled

4. Use the correct gauge of wire and the correct

Governor, Wiring Guidelines

Special Instruction, Perkins Electronic Controlled

Special Instruction, Perkins Electronic Controlled

The controller for the ECG must be installed in

The temperature of the controller must be within the

1.50 mm2 (AWG 16)

1.0 mm (AWG 18)

6.7 m (22 ft)

The vibration of the controller must be within the

2.50 mm (AWG 14)

The recommended gauges for the wire and the

Random vibration ..................... 6 G at 40 to 2000 Hz

Note: Construct the wiring harness with a cable that

1. Install the controller for the ECG.

Installation of the Controller