KENR6237

08 March 2007

Special Instruction
Operation of the ECG Software ........................ 18
Hardware requirements ................................. 18
i02589674
Installation of the Hardware ........................... 19
Installation of the ECG Software ................... 19
Perkins Electronic Controlled Basic Software Operation ................................. 20
Operating the ECG Software ......................... 20
Governor “Progress Display Screen” ............................. 21
Navigating Around the ECG Software ........... 21
SMCS Code: 19084 Software Menus and Options ............................ 21
File Menu ....................................................... 21
400 Series Industrial Engines “Save ECG to Cal to File” .............................. 22
(S/N: HB, HD, HH, HL, HN, HP, HR, GG , “View Cal File Comments” ............................. 24
GH, GJ, GK, GL, GM, GN, GP, GQ View Text File ................................................ 25
Convert Commands ....................................... 25
“Convert ECG Cal to Text” ............................. 25
Table of Contents “Convert Cal File to Text” ............................... 25
“Convert Cal File to Strategy” ........................ 26
Introduction ........................................................... 2 Calibrate Menu .................................................. 27
Understanding the System ................................... 2 “Download Cal File to ECG” .......................... 27
Components of the Electronic Controlled Governor “Compare ECG Cal to File” ........................... 28
(ECG) .................................................................. 2 “Calibration Wizard” ....................................... 29
Controller ........................................................... 2 “Monitor Menu” .................................................. 32
Speed Sensor ................................................... 3 “Parameter View” ........................................... 32
Actuator ............................................................. 3 “Parameter Plot” ............................................ 33
ECG Software ................................................... 3 “Make PID Gain Adjustment” from the “Plot
Programmable Features ................................... 4 Display” window ........................................... 34
Selection Options for Engine Speed .............. 4 “Change Plot Setup” ...................................... 35
Installing the Hardware ..................................... 4 “Display Faults” .............................................. 35
Wiring Guidelines .......................................... 5 “Control Strategy” .......................................... 36
Wiring Lengths ............................................... 5 “Parameter List” ............................................. 36
Installation of the Controller .............................. 5 “Configure Menu” .............................................. 38
Controller Wiring ............................................ 6 “Configure the Serial Port” ............................. 38
Basic Installation for the Control System for 1500 Configure the “Demonstration Mode” ............ 38
rpm and 1800 rpm ....................................... 8 Configure a Custom Serial Port ..................... 39
Installation of the Speed Sensor ....................... 8 “Help Menu” ...................................................... 39
Engine Speed Setpoint Wiring Trim Analog “Help Topics” .................................................. 39
Input ................................................................ 9 “About ACT” ................................................... 40
Switched Inputs for the Engine Speed User Manual .................................................. 40
Setpoints ......................................................... 10 Calibrating the Features of the ECG ................. 40
Switch Wiring .................................................... 11 The Calibration Guide ....................................... 40
Single Switch Mode ....................................... 11 Calibration Categories ................................... 41
Two-Speed Mode .......................................... 11 Calibrating the Controller ............................... 41
Three-Speed Mode ........................................ 12 Saving a Calibration Set to a File .................. 42
Four-Speed Mode .......................................... 12 Calibrating the Controller with a Saved
Glow Plug Control Wiring .................................. 13 Calibration File ............................................. 42
Installation of the Wiring for the Glow Plug Understanding the Calibration Parameters of the
Control ......................................................... 13 ECG ................................................................. 42
Autocrank Wiring ............................................... 14 Configuration Modes for the Switch ................. 43
Installation of the Autocrank Wiring ............... 15 Engine Start “Calibration Parameters” .............. 45
Auxiliary Output Wiring ...................................... 16 Glow Plug Control .......................................... 45
Engine Protection Input Wiring .......................... 17

1
 “Autocrank” .................................................... 45 • Speed sensor
Diagnostic Calibration Parameters .................... 46
Engine Protection Input ................................. 46 • Actuator
Actuator Calibration Parameters ....................... 47
Auxiliary Outputs ........................................... 47 • Calibration software
Droop Governing ........................................... 48
Troubleshooting ................................................. 48 Controller
“Governor Gain Calibration Parameters” .......... 48
PID Gain Settings Response Plots ................ 48
Troubleshooting Guidelines ........................... 49
Fault Codes ................................................... 50
Flow Chart for the Calibration Setup and
Configuration Parameters ........................... 51
Glossary of Terms ............................................. 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 g01297677
Illustration 1
provided to prevent loss of engine control that
may result in personnel injury or death. 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
The electronic controlled governor (ECG) provides a
lever with a proportional actuator. The controller for
means of controlling the engine speed by adjusting
the ECG may be programmed to operate at four
the fuel control lever with an actuator.
different speeds. The controller for the ECG also
operates in isochronous mode or droop mode. The
Understanding the System droop mode can be selected by the operator up to
8%.
A microprocessor based controller processes the
signal from the speed sensor. The signal that is The controller for the ECG is programmed by the
received from the speed sensor is then compared to software. The controller has no manual adjustments.
the desired speed setting.

The output of the controller is a pulse width modulated

signal. The output signal drives a proportional
actuator. The actuator is connected to the engine’s
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

2
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

g01297366
Illustration 2
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

g01297741
Illustration 3 g01297765
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.

3
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 Yes
excessive coolant temperature
“Engine start calibration” For engines that require special start-up operation such as warm No
up speed, reduced governor gains or missing speed signal
“Glow plug control” For enhancing cold start capability by using an auxiliary output Yes
“Overspeed/Underspeed - No
Protection”
“Proportional Integral Allows the governor response to be adjusted by the operator No
Derivative Gain adjustment
(PID)”
“Switched speed setpoint Allows for multiple speed settings by using switches Yes
inputs”
“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.

The ECG expands the Perkins line of programmable Selection Options for Engine Speed
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 Table 2
configuration that will permit the controller to adapt to Selection Options for Description
a variety of applications for governing of the engine. Engine Speed

The programmable features that are available with “No analog input” Use a speed switch in
order to select up to four
the ECG are shown in Table 1.
different speeds
The ECG software must be correctly installed in “Speed trim” Use a speed potentiometer
order to configure the selected programmable (analog output) in order
feature. To incorporate any of the programmable to trim the speed switch
features, refer to this Special Instruction, “ Perkins selected set speed
Electronic Controlled Governor, Installing the
Hardware” section of this manual. To calibrate any of Installing the Hardware
these programmable features, refer to this Special
Instruction, “ Perkins Electronic Controlled Governor, The hardware for the ECG will require setup.
Calibrating the Features of the ECG” section of this
manual for further details. 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:

4
• Special Instruction, “ Perkins Electronic Controlled 4. Use the correct gauge of wire and the correct
Governor, Wiring Guidelines” length of wire. Refer to Table 4 for the correct
gauge and the correct length of wire. Excessive
• Special Instruction, “ Perkins Electronic Controlled length of wire or the incorrect gauge of wire may
Governor, Installation of the Controller” cause increased wire resistance. Increased wire
resistance can limit the current to the actuator.
• Special Instruction, “ Perkins Electronic Controlled Limiting the current may prevent full actuator
Governor, Installation of the Speed Sensor” travel. Increased resistance in the wiring can also
result from poor wiring. It is important to use good
Wiring Guidelines quality terminations and the correct technique for
crimping during wiring. Use Tooling (A) in order to
Table 3 use good terminations. Use Tooling (B) in order to
Part Number Description crimp the terminal to the wire. Terminations must
be resistant to moisture in order to prevent a short
A 20198 Connector kit circuit and corrosion.
B CH11155 Crimping tool
Wiring Lengths
The controller for the ECG must be installed in Table 4
a location when the effects of vibration and the
Wiring Specifications
temperature is within the specified ranges.
Gauge Length
The temperature of the controller must be within the
2.50 mm (AWG 14)
2
20 m (66 ft)
following range:
1.50 mm2 (AWG 16) 10 m (33 ft)
The temperature range is 40° to 85°C (104° to 153°F).
1.0 mm (AWG 18)
2
6.7 m (22 ft)
The vibration of the controller must be within the
following range: The recommended gauges for the wire and the
maximum lengths of connecting wires for different
Random vibration ..................... 6 G at 40 to 2000 Hz sizes of actuators or the ECG is shown in Table 4.
The wire length is calculated by using the total length
Refer to this Special Instruction, “ Perkins Electronic of wire that is used to connect the actuator to the
Controlled Governor, Installation of the Controller” controller and from the controller to the power supply.
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
1. Install the controller for the ECG. preferably shielded with foil.

2. Connect the power leads directly to a switched Installation of the Controller

power source (battery). Install a 10 amp slow blow
fuse in the battery wire. The dimensions of the controller are shown in
Illustration 5. The J1 connector is gray in color. The
3. Install a shielded cable in order to receive the J2 connector is black in color.
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.

5
 Controller Wiring

g01300072
Illustration 6
Typical view of the J1 connector

g01300075
Illustration 7
g01299544 Typical view of the J2 connector
Illustration 5
A view of the dimensions of the controller
Refer to Table 6 for the J1 pin locations. Refer to
Table 5 Table 6 for the J2 pin locations.
Dimensions of the Controller
1 94 mm (3.70 inch)
2 101.6 mm (4.0 inch)
3 7.39 mm (0.291 inch)
4 75 mm (2.953 inch)
5 117.04 mm (4.608 inch)
6 101.6 mm (4.0 inch)
7 36.245 mm (1.427 inch)

6
Table 6

Function Pin Information Remarks

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

7
Basic Installation for the Control System for 1500
rpm and 1800 rpm

g01300420
Illustration 8
(1) J1 connector (gray) (4) Battery ground -ve 12v (7) J2 connector (black)
(2) Actuator (5) Battery +ve 12v
(3) Speed sensor (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.

8
 Engine Speed Setpoint Wiring Trim
Analog Input

g01301437
Illustration 9
Typical example of an installed speed sensor
g01302234
Illustration 11
The speed sensor is a magnetic pickup sensor that
(1) Controller
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.

g01343599
Illustration 12
(1) Controller

The controller for the ECG features an analog speed

input.

Illustration 10
g01301436 In order to incorporate this feature, the analog
input must be wired to an external potentiometer.
(1) Controller
Potentiometer resistances of 3 k to 5 k ohms are
recommended. Refer to Illustration 11 for further
A shielded twisted wire must be used for all speed
information.
sensor wiring. The shielded wire must be grounded
to the controller for the ECG. Refer to Illustration 10
In order to calibrate the parameters of this feature,
for further information.
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.

9
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.

Refer to this Special Instruction, “ Perkins Electronic

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
Special Instruction, “ Perkins Electronic Controlled
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) (3) Speed 2

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
Three-Speed Mode

g01344536
Illustration 15
Typical example of a wiring diagram for the three-speed mode
(1) Controller (3) Speed 2
(2) Speed 1 (No connection) (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 (3) Speed 2 (5) “Speed 4”
(2) Speed 1 (4) Speed 3

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 (3) Auxiliary output
(2) Autostart switch input (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 (3) Auxiliary output
(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 NOTICE
vbat)”. If using the autocrank feature, ensure that the
autocrank feature has been calibrated prior to
Install the wiring to the electric starting motor relay connecting to the ECG controller.
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) con-
troller is not calibrated for the autocrank feature
Note: If the auxiliary output draws more than 200 and the crank motor relay is connected, the en-
mA, the auxiliary output will be disabled and a fault gine may start as soon as power is applied to the
code will be activated. controller. This could result in the possible loss of
engine control which could result in personal in-
Connect the power supply side of the relay switch to jury or death. Be sure to calibrate the autocrank
the Vbatt+ connection. Connect the remaining side of feature before you connect the ECG controller.
the relay switch to the solenoid of the electric starting
motor.
A wiring diagram for the autocrank is shown in
Once the input for the ECG is wired, the parameters Illustration 18.
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 (3) Auxiliary output

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

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

The controller for the ECG offers a feature for an Hardware requirements
engine protection shutdown. The engine protection
shutdown protects against adverse operating The following hardware is required in order to operate
conditions such as low oil pressure or high coolant the ECG software:
temperature.
• 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 • CD-ROM drive
switch must be to the “ground potential”.
• Serial port with a DB-9 connector that is capable of
A wiring diagram for the engine protection is shown 9600 baud communication
in Illustration 21.
• Windows 2000/XP software
The sensors must be wired in parallel if more than
one sensor is used. A wiring diagram of the sensors • 64 MB of available RAM memory and an hard disk
that are wired in parallel is shown in Illustration 22. space of at least 2.0 MB of free disk space

Once the input for the engine protection is wired, the • SVGA video card and monitor. Capable of 256
parameters require calibration. Refer to this Special colors and 800 by 600 display.
Instruction, “ Perkins Electronic Controlled Governor,
Calibrating the Features of the ECG”.

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 (3) Harness (5) RS-234 cable
(2) OEM connection (4) PC (6) Interface module

A nine pin RS-232 cable is used in order to connect Installation of the ECG Software
the ECG to the PC. A proprietary interface module is
required to connect the ECG to the communication The ECG software may be automatically installed
port on the PC. 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 Note: Close all applications in order to prevent
connections. 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 1. Ensure that the power supply to the PC is switched
end of the RS-232 cable to the interface module. ON. Insert the software disk for the ECG into the
CD-ROM drive. Installation of the ECG software
3. Connect the interface module to the ECG by should now begin. The ECG software may also
using the connector on the harness. The interface be installed by selecting the CD-ROM drive in
harness is inserted to the J1 (Gray) connector that Windows Explorer.
is located on the controller. The interface harness
is inserted to the J1 (Gray) connector of the OEM 2. Follow the prompts that are shown in the ECG
harness. software for installing the ECG software . The
operator may select the default directory. The
A diagram of the hardware is shown in Illustration 23. operator may specify individual settings.

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
Special Instruction, “ Perkins Electronic Controlled
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
Special Instruction, “ Perkins Electronic Controlled
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 Software Menus and Options
the user of the progress of the communication
procedures. The “Progress Display Screen” will close The ECG software has five main menus. The five
automatically when the procedure is complete. main menus have the following available options:

A typical view of the “Progress Display Screen” is • File Menu

shown in Illustration 24.
• 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 • Configure Menu
Electronic Controlled Governor, Software Menus and
Options” for further information. • Help Menu
The following procedures will assume that the cursor File Menu
is at the “Main Menu” screen. Use the following
commands in order to navigate around the “Main The “File ” menu allows the user to perform the
Menu” screen: following operations:

• Use the mouse in order to select the menu. Use • Viewing files
the mouse in order to navigate around the menu.
• Saving files
• Use the left mouse button to execute a command
or accept a condition. • Converting files
• 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.

g01308657
Illustration 27

23
 g01318285
Illustration 28

4. The current calibration values from the controller 6. A message will be displayed when the file has
will be read by the ECG software. The ECG been created successfully. The name of the file
software will prompt the operator to add comments that is shown in the message is the name of the
to the software file. The prompt for the software file that was entered in Step 2. An example of the
is shown in Illustration 27. If the “Yes” option message is shown in Illustration 29.
is selected, the “Cal File Comment List” will
appear. The “Cal File Comment List” is shown Note: The “Save ECG Cal to File” command stores
in Illustration 28. In order to enter comments, the calibration data as a software file. The software
type the comments one at a time and select the file cannot be printed directly. The software file
“Save Edit” option. In order to edit the comments, cannot be viewed directly. Printing and viewing must
select the comment on the top line of the “Cal File be done from a converted text file. Refer to this
Comment List” and edit the comments. In order to Special Instruction, “ Perkins Electronic Controlled
save the new comments, select the “Save Edit” Governor, Convert ECG Cal to Text” and the Special
option. Comments can be deleted by selecting Instruction, “ Perkins Electronic Controlled Governor,
the comment and selecting the “Delete” option. Convert Cal File to Text” for further information.
Select the “Cancel” option in order to close the
window. The calibration file will still be created if “View Cal File Comments”
the “comment editor screen” is cancelled.
The “View Cal File Comments” option allows the
5. Select the “OK” option on the “comment editor operator to display the “Cal File Comments” that are
screen” in order to save comments. attached to a calibration file.

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”.

g01315904
Illustration 29

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 ECG Cal to Text”

• “Convert Cal File to Text”
• “Convert Cal File to Strategy”
The “View Text File” command may be used to view
the text file.

“Convert ECG Cal to Text”

The “Convert ECG Cal to Text” command allows the

Illustration 30
g01316575 operator to create a text file. The text file is created
by using calibration data for viewing or for printing
1. Select the “File” option. Select the “View Cal from any text editor utility in Windows software.
File Comments” option. The ECG software will
display a list of files at the top of the “View Cal File A printed copy of the calibration data may be useful
Comments” window. The “Cal File Comments” for future reference.
will be displayed on the lower half of the “View
Cal File Comments” window. The “View Cal File Use the following process in order to “Convert ECG
Comments” window is shown in Illustration 30. Cal to Text”.

2. Select the desired “Cal File” in order to highlight 1. Select the “File” option. Select the “Convert ECG
the “Cal File”. Use the UP and DOWN arrow keys Cal to Text” option.
in order to navigate through the “Cal File”.
2. The ECG software will prompt the operator to
3. Select the “Cancel” option in the “View Cal File enter a name in order to save the text file. Select
Comments” window in order to close the “View a file and select the “Save” option.
Cal File Comments” window.
3. The ECG software will prompt the operator to
Note: The comments are created or the comments enter comments. Select the “No Comments”
are edited when the files are created. Refer to this option if no data is required. Enter comments and
Special Instruction, “ Perkins Electronic Controlled select the “Save Comments” option in order to
Governor, Save ECG Cal to File” for further save the comments.
information.
The ECG software will read all of the calibration
View Text File values from the saved file. The ECG software will
create a text file in order to save the text file with the
The “View Text File” allows the operator to view text. parameter names, values and units.

Use the following process in order to “View Text “Convert Cal File to Text”
Files”.
The “Convert Cal File to Text” command allows the
1. Select the “File” option. Select the “View Text File” operator to convert a previously saved calibration file
option. to a text file. The text file can be used for viewing
or printing using a text editor utility in the Windows
2. The ECG software will prompt the operator for a software.
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.

3. The ECG software will prompt the operator to

enter a name in order to save the text file. Select
the “Save” option.

4. The ECG software will prompt the operator to

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

The ECG software will read all of the calibration “Convert Cal File to Strategy”
values from the controller. The ECG software will
create a text file in order to save the text file with the The “Convert Cal File to Strategy” command is
parameter names, values and units. A view of the used in order to convert old ACT files for use with
text file window is shown in Illustration 31. 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.

2. The ECG software will prompt the operator to

enter a name in order to save the text file. Select
the “Save” option.

3. The ECG software will prompt the operator to

enter comments. Select the “Save Comments”
option. If no comments are required, select the
“No Comments” option.

The ECG software will read all of the calibration

values from the controller. The ECG software will
create a text file in order to save the text file with the Illustration 32
g01317763
parameter names, values and units.
2. Select the “Cal File” that requires downloading. A
Calibrate Menu view of the “Choose a Calibration file to download”
window is shown in Illustration 32.
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. g01317782
Illustration 33
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.
g01317792
Illustration 34
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.
1. Select the “Calibrate” option. Select the “Download
Illustration 34 is displayed when the download is
Cal File to ECG” option.
completed.

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”.

g01318067
Illustration 37

g01318054
Illustration 35

1. Select the “Calibrate” option. Select the “Compare

ECG Cal to File” option. Illustration 35 shows the
“Choose a Calibration file to compare” window.
g01318066
Illustration 38

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
g01318056 4. If mismatches are shown, select the “Save to
File” option. The “Save to File” option is shown in
2. Select the calibration file that requires comparing. Illustration 37.
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.

g01318167
Illustration 39

g01319278
Illustration 41

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.

g01318124
Illustration 40

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

3. The “Calibration Wizard” will prompt the operator Note: Select the “Cancel” option in order to abort the
to start the “Calibration Wizard” with one of the “Calibration Wizard”.
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.

g01319340
Illustration 43

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 7. Select the “Next” option in order to confirm and
through the process for calibration by using a download the selected values. The selected
series of questions. The “Calibration Wizard” will values will download the new calibration to the
prompt the operator to confirm that the values are ECG. The new calibration values will reset all of
correct. The “Calibration Wizard” window is shown the parameters in the ECG. Illustration 45 shows
in Illustration 44. 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”
Note: The engine may be fine tuned by adjusting
g01319364
the PID gains. The PID gains are contained in
Illustration 45 the “Parameter Plot Screen”. Refer to this Special
Instruction, “ Perkins Electronic Controlled Governor,
Monitor Menu” for further information.

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
shown in Illustration 46.

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.

1. Select the “Monitor” option. Select the “Parameter

Plot” option.

33
 g01320203
Illustration 47

2. The “Parameter Plot” window is displayed. The “Make PID Gain Adjustment” from the “Plot
“Parameter Plot” window automatically starts to Display” window
read the previously saved configuration. The
controller requests the parameter values. The Use the following process in order to “Make PID Gain
“Parameter Plot” window is shown in Illustration Adjustment” from the “Plot Display” window.
47.
1. In order to make adjustments in the appropriate
The controller transfers the data to a PC. The data field, select one of the fields for the PID gain
may be transfered at various speeds. The transfer adjustment. A description of the fields for the PID
of the data depends on the number of parameters gain adjustment are shown in Table 8.
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”
for further information.

34
Table 8
Code Description
P Proportional gain
I Integral gain
D 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.

3. Select the “OK” option in order to save the data “Display Faults”
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
Note: The “Calibration Wizard” will automatically set automatically be displayed.
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

1. Select the “Monitor” option. The application To clear historical faults, select the “Clear Historical
will display the “Diagnostic View” window. The Faults” option in the “Diagnostic View” window.
“Diagnostic View” window is shown in Illustration
48. The “Diagnostic View” window will be updated “Control Strategy”
when the controller sends the fault flags status.
The “Control Strategy” option allows the operator
2. Select the “Pause” option in order to stop to check the version of the control strategy that is
automatic updates of the screen. The “Pause” being used. This information may be required for
option will automatically change to a “Start” identification of the strategy and for future use.
option. Selecting the “Start” option will restart the
automatic updating of the faults. “Parameter List”

Note: The “Display Faults” option will automatically The “Parameter List” option allows the operator
pause if any other feature that communicates with to adjust the parameters that are displayed in the
the controller is used. “Parameter List” window.

The controller has the ability to recall faults that have Use the following process in order to display the
been cleared. The controller has the ability to recall “Parameter List”.
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.

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

1. Select the “Monitor” option. Select the “Parameter

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
to this Special Instruction, “ Perkins Electronic
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
to this Special Instruction, “ Perkins Electronic
Controlled Governor, Parameter View” for further
information.

Use the following procedure in order to close the

“Parameter List”: Illustration 50
g01343998

1. In order to close the “Parameter List” window, 2. Selecting the “Save” option will prompt the
select the “X” in the top right hand side of the title operator to enter a name in the “File name” field.
bar. Illustration 50 shows the “Choose a file name to
save the view setup to” window. Type in a name
Use the following process in order to open the in the “File name” field that reflects the purpose of
“Parameter List” window: the saved configuration. Select the “Save” option.
1. The “Parameter List” window must be closed and Use the following procedure in order to open a
reopened if any changes are made in order to previously saved “View Configuration”:
make changes effective.

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 following process in order to configure a Use the “Help Topics” option in order to search for
custom serial port. specific information.

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

1. Select the “Help” option. Select the “Help Topics” • Compact disc
option. The “Help Topics” window is displayed. The
“Help Topics” window is shown in Illustration 52. • Perkins Service and Parts Information (SPI)
The “Contents” option will provide an outline of the
software applications. The software applications • Perkins Manual
are listed by menu items. The “Index” option will
enable the operator to locate a specific topic by Calibrating the Features of the ECG
using an alphabetical listing. The “Index” option
will enable the operator to locate a specific topic If the operator does not have any specific
by typing a word or phrase into the search field. requirements for calibration, choose the “Download
The search field is located at the top of the “Help Cal File to ECG” option. Refer to this Special
Topics” window. Instruction, “ Perkins Electronic Controlled Governor,
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
“About ACT”
the various features of the ECG in order to work with
the application.
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 Note: Before proceeding, ensure that the operator
has completed the installation of all required
support.
hardware for the system. Ensure that the operator is
User Manual trained in using the ECG.

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
Instruction, “ Perkins Electronic Controlled Governor,
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 2. If no icon exists, select the “Start” option on
of any parameters in order to start basic operation of the PC. Select the “Programs” option. Select
the ECG. All parameters are preset to values that will the “Perkins Engine” option. Select the “ECG
work with many applications. Calibration Tool” option.

Calibrating the Controller 3. Ensure that the communication port designation

in the ECG software matches the serial port on
Ensure that the controller is connected to the the PC. The “Configure Menu” will be displayed.
communication port. Ensure that the controller is If the communication port assignment requires
powered up. changing refer to this Special Instruction, “ Perkins
Electronic Controlled Governor, Configure Menu”
Use the following process in order to calibrate the for further information.
controller.

1. If an icon exists for the calibration tool, double

click the icon in order to start the software.

41
The “Calibration Wizard” may be used for specific The ECG software restricts the operator from
calibration. The “Calibration Wizard” is an interactive entering values outside the specified range. The
guide that is used in order to help in setting up the values outside the specified range are entered. A
controller to specific requirements. Refer to this warning will be displayed. A list of available ECG
Special Instruction, “ Perkins Electronic Controlled calibration parameters are shown in Table 11.
Governor, Calibration Wizard” for further information.
NOTICE
All calibration settings are automatically saved in The range is fairly wide and it is possible to enter
the controller. The calibration settings remain in the values in excess of the capability of the application.
memory after shutdown. Saving may be helpful in The range is limited for engine protection and human
case of failure of the controller or for calibrating in a safety. The limits do not reflect the capability of
similar application at a later date. any application that may be driven. It is possible
to command engine speeds up to 2500rpm with
Saving a Calibration Set to a File the ECG software. The engine may not be able to
operate at this speed due to mechanical limitations.
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

to this Special Instruction, “ Perkins Electronic
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
Category Parameter 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”
“Governor Gain Calibration” “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 input configuration “Speed_type” Magnetic pickup

“Autocrank crank time” Starting motor solenoid time (seconds)

“Autocrank max tries” Number of “autocrank” attempts
Engine start calibration “Autocrank rest time” Rest time between “autocrank” attempts
(Seconds)
“Glow plug time” Glow plug time (seconds)
“Overspeed_rpm” Actuator shutdown speed (Maximum)
Diagnostic calibration
“Underspeed_rpm” “Actuator shutdown speed” (Minimum)
“Aux_Output_rpm” Drive auxiliary output when engine speed
is above this rpm
Actuator output calibration “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.

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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.
The engine is started. The engine moves from the cranking
mode to the run mode. The engine speed will increase from
“SET_SPEED_MIN” to “SET_SPEED_WARMUP” at the
“RAMP_UP_RATE”.
Engine speed remains at the warm up speed for
“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.
The engine is started. The engine moves from the cranking
mode to run mode. The engine speed will increase from
“SET_SPEED_MIN” to “SET_SPEED_WARMUP” at the
“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
“SET_SPEED_MIN” to “SET_SPEED_WARMUP” at the
“RAMP_UP RATE”.
Engine speed remains at the warm up speed for
“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
Instruction, “ Perkins Electronic Controlled Governor,
Calibration Wizard” for further information. The
calibration parameters that require a configuration
are shown in Table 13.

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 the“auxilairy output 2” that requires the configuration.
(1)

“GLOWPLUG_TIME” The parameter is used to specify the preheat time, in

seconds, before the “Autocrank” relay is engaged. (2)
(1) Refer to this Special Instruction, “ Perkins Electronic Controlled Governor, Auxiliary outputs” for further information.
(1) Refer to this Special Instruction, “ Perkins Electronic Controlled Governor, Auxiliary outputs” for further information.
(2) 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) Refer to the appropriate Operation and Maintenance Manual, “Starting the Engine” for further information.
(2) Refer to the appropriate Operation and Maintenance Manual, “Starting the Engine” for further information.
(2) Refer to the appropriate Operation and Maintenance Manual, “Starting the Engine” for further information.

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
Instruction, “ Perkins Electronic Controlled Governor,
Calibartion Wizard” for further information . The
calibration parameters that require a configuration
are shown in Table 15.

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
Instruction, “ Perkins Electronic Controlled Governor,
Glow Plug Control Wiring” for further information.
Refer to this Special Instruction, “ Perkins Electronic
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.

The “Calibration Wizard” can be used in “Governor Gain Calibration Parameters”

order to select the following options:set
the “AUXILIARY_OUTPUT_MODE” and the PID Gain Settings Response Plots
“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:

• 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

g01345541
• “Autocrank” mode Illustration 53
Typical example of the PID gains too low
• Simulates the on board ECM LCD (Desired rpm) 1
(Actual rpm) 2
• Glow plug control (Time) X
(rpm) Y
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
 g01345551 g01345760
Illustration 54 Illustration 57
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 (Desired rpm) 1
(Time) X (Actual rpm) 2
(rpm) Y (Time) X
(rpm) Y

g01345556
Illustration 55
g01324068
Illustration 58
Typical example of the integral gains too low
Typical view of a preferable response
(Desired rpm) 1
(Actual rpm) 2 (1) Remove the engine load
(Time) X (2) Add to the engine.
(rpm) Y (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
Tool Part Number Part Description Qty
A - Digital Multimeter 1
g01345569
Illustration 56
Use Tooling A to measure the frequency and the duty
Typical example of the derivative gains too high
cycle.
(Actual rpm) 1
(Desired rpm) 2
(Time) X
Use the following procedure in order to troubleshoot
(rpm) Y 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
1 ECG unit not calibrated Yes Calibrate ECG unit
2 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
3 Engine speed unusually low YES Check the parameter
settings
Ensure that load is not
greater than engine
capacity
4 Engine shutdown due to engine Yes Check the parameter
protection input settings
Check the fault that
may have triggered the
protection input
5 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.
8 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)
9 Limiting excessive actuator No Check the actuator for a
current short to ground
Check the parameter
settings
Ensure that the load is
not greater than engine
capacity
10 The input for the engine speed No (Only active in Autocran
signal is missing. mode)
Check the speed sensor
wiring
Check the starter motor
11 “Autocrank” is unable to start the No Check the engine for
engine 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
contact your Perkins dealer
or your Perkins distributor
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,
contact your Perkins dealer
or your Perkins distributor
for assistance
14 The actuator might be No Check the actuator wiring
disconnected. The cctuator and actuator resistance
has an open circuit Resistance should be less
than 10 ohms

The controller is capable of identifying certain fault 4. The controller will attempt to shut down for some
conditions and alerting the operator of the fault faults. The controller will not permit starting after a
conditions. A flashing LED indicates a fault condition. reset when faults 1, 5 and 8 occur.
The list of faults is shown in Table 18.
Flow Chart for the Calibration Setup and
The following procedures should be noted: Configuration Parameters

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

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