Genset Controls

HEINZMANN

Controls Actuators Displays Accessories

 HEINZMANN Australia Table of Contents

Products
ExPErtisE in EnGinE HEINZMANN AUSTRALIA
GEnErator Controls Products
With the acquisition of DAWSON
TECHNOLOGY, the HEINZMANN Group has
Products Genset Controls .............................................................................................. 4
gained a market leader in engine controls and
• Generator Set Applications ....................................................................... 5
power generation applications. The Australian
company has been serving both local and Controls Actuators ............................................................................................................. 6
international markets for over 30 years and Controls for gas and diesel • Electric Actuators ......................................................................................... 6
now operates under the name of Heinzmann fuelled reciprocating engine • Hydraulic Amplifiers .................................................................................... 7
Australia Pty Ltd. applications
Displays ............................................................................................................... 8
Together with engine control solutions,
• Generator Display ........................................................................................ 8
HEINZMANN Australia designs and
• Utility Grid Master Display ........................................................................ 8
manufactures grid-parallel controls, hydraulic
• Temperature Display .................................................................................. 8
actuators and control accessories. HEINZMANN Actuators

Services
Australia also provides professional engineering Electric and hydraulic actuators Control Accessories ...................................................................................... 9
and commissioning services support. tailored for large reciprocating • Temperature Scanner ................................................................................. 9
engines • Digital I/O Expansion Module ................................................................ 9
HEINZMANN Australia is achieving the
highest quality standards in every aspect of • Speed Sensor Expander ............................................................................ 9
their process (including design, engineering, • Dual Redundant Overspeed Trip ........................................................... 9
manufacturing, sales & after-market service
Software & Diagnostics ............................................................................ 10
support).
• Configuration Software ............................................................................ 10
Displays
HEINZMANN Australia has attained ISO • Tuning Software ......................................................................................... 10
9001:2008 quality management standard Engine, generator and utility
• Temperature Scanner Software ............................................................ 10
accreditation. master displays
• Logging Software ....................................................................................... 10
• Data Hub Gateway ................................................................................... 10

Design & Production .................................................................................. 11

• Control System Design & Production ................................................. 11
Accessories
Quality ISO 9001
Services Complete R&D and Technical Support ............................................. 12
Certified System Extensive range of engine
• Qualified & Experienced Team .............................................................. 12
control accessories

Installations
Installations Installation Examples ................................................................................ 14

Software
Smart software for annunciation,
configuration and diagnostics

2 www.heinzmann.com.au Phone: +61 7 3868 3333 3

 Genset Controls

Products
Si-TEC Control Series Generator Set Controls GENERATOR set Applications
Heinzmann Australia Pty Ltd manufactures HEINZMANN Australia genset controls comprise of the following
the exceptional range of Si-TEC controllers governor and generator control features:
TGC - Total Generator Control
for reciprocating applications. The Si-TEC Key features The TGC is used for single or multiple islanded generator set applications
range of controllers integrate seamlessly
Precise speed governing where utility paralleling functions are not required.
into the majority of generator drive
Dual redundant MPU inputs Digital governor functions are integrated with generator control functions
applications. (i.e. synchronising, load sharing, etc.)
Automatic start sequence
Development of the Si-TEC controller Comprehensive actuator interface support
family commenced in 1992, and as (incl. HEINZMANN all-electric)
technology has evolved, several new Wide range of PIDs
generations of engine governors and Comprehensive AVR interface support
Auto synchronising Si-TEC Xtend TGC is available in 2 variations:
generator controls have been introduced.
Today, more than 4000 Si-TEC systems are kW control & load share (3-phase) TGC-D
kVAr/PF control & load share For diesel fuelled reciprocating engines
in operation worldwide.
Actuator/valve linearization curves TGC-G

Services
Coupled with the sale of Si-TEC products, For gas fuelled reciprocating engines
Flexible configuration
HEINZMANN Australia offers professional
User-friendly tuning software (PC tune)
engineering and commissioning services,
Extensive system diagnostics
delivering excellence in customer support
Optional I/O expansion
from project concept through to practical
CGC - Co Generator Control
completion.
The CGC is used for generator set applications where utility paralleling
For detailed product information, please functions are required.
refer to our product data sheets available Digital governor functions are fully integrated with generator control
at: www.heinzmann.com.au/download functions (i.e. synchronising, kW load control, kVAr/PF control, etc.)

Si-TEC Xtend TGC is available in 2 variations:

HEINZMANN Australia CGC-D
For diesel fuelled reciprocating engines
provides:
CGC-G
For gas fuelled reciprocating engines

Installations
Islanded & Grid-Paralleled
Generator Controls

Options for Diesel and

Gas Fuelled Applications

Multiple PID Support for

Large Engine Tuning

4 www.heinzmann.com.au Phone: +61 7 3868 3333 5

 Actuators

Products
HEINZMANN Actuators Electric Actuators HYDRAULic AMPLIFIERS
For more than 100 years, HEINZMANN The powerful HEINZMANN range of actuators have been extensively HEINZMANN Australia provides hydraulic amplifiers for large engine control, via mechanical input (i.e. with
has been developing and manufacturing applied on engines where forces up to 180 Nm are required to electric actuator) or electrical input (i.e. with in-built electro-hydraulic actuator).
high-performance actuators. The portfolio control the fuel rack or fuel metering valves. This series of gear-
type all-electric actuator is based on a DC disc motor and gear
Key features
encompasses electric actuators for any type of
transmission, with options for 36° or 42° travel. Minimal overshoot
engine, for original fitment, or retrofitting.
Shock resistant cast iron casing
Key features
Recognised for their fast and precise Billet power piston & output shaft
Easily fitted to any engine
performance, HEINZMANN actuators are Output shaft support bush (oil fed)
Proven reliability and long-life cycle
renowned for their robust and reliable design - Wear preventative coating for extended service life
Covering any field of application
reflecting the highest quality demands we
make on our products.

HEINZMANN Australia has developed a range

StG 6/6V/10 Electric HA14M/HA22M Hydraulic Amplifiers
of mechanically and electrically controlled
Actuator The mechanically controlled HA14M/HA22M amplifiers are pilot operated
hydraulic amplifiers capable of providing the
Electric actuators used for linear servo actuators, which interface with the actuator/governor output

Services
force to operate the control valve of steam reciprocating engine applications shaft via a mechanical linkage.
turbines or fuel control linkages of large (typically direct positioning of
reciprocating engines. fuel pump or gas valve). Fast and
efficient performance with position
feedback.

HEINZMANN Australia StG 16/30/40 Electric HA14E/HA22E Hydraulic Amplifiers

provides: Actuator The electrically controlled HA14E/HA22E amplifiers are pilot operated
Electric actuators used for linear servo actuators, which are used in conjunction with the Si-TEC
reciprocating engine applications Xtend CGC/CGC-ET governor (0 – 200 mA output), Woodward electronic
Electric Rotary Actuators (typically direct positioning of governors, etc..
with Gearing fuel pump or gas valve). Fast and
efficient performance with position
Hydraulic Actuators feedback.
Mechanically or
Electrically Controlled

Installations
StG 64/90 Electric
Actuator
Electric actuators used for
reciprocating engine applications
(typically direct positioning of
fuel pump or gas valve). Fast and
efficient performance with position
feedback.

6 www.heinzmann.com.au Phone: +61 7 3868 3333 7

 Displays & Control Accessories

Products
System Components Displays Control Accessories
HEINZMANN Australia is your single source The HEINZMANN Australia range of displays provides HEINZMANN Australia also provides a range of control accessories that seamlessly integrate with the Si-TEC
partner, providing all system components for comprehensive and user-friendly information for operators, providing range of controllers. These include remote I/O modules for digital and analogue I/O expansion. Also included
complete, fully integrated solutions from a a generator metering panel, along with monitoring & protection. are stand-alone devices such as MPU signal expanders, temperature scanner (32-ch) and the new Sapphire II
protection device.
single supplier.

In addition to controllers and actuators,

we develop, produce and supply remote
Opal II Generator Display Temperature Scanner
displays (for metering of generator
Remote display of the Si-TEC Xtend Temperature monitoring unit up to 32 channels (T/C, RTD or “Combo”
parameters or temperature readings),
control (via CAN bus interface). units). Also includes alarm output and Modbus RS485 comm. port for
temperature scanners, I/O units and Metering of essential generator remote (DCS) monitoring.
overspeed protection devices. parameters that include generator
“voltage”, “frequency”, “real power”,
“power factor” (lag & lead).
Includes overspeed protection.

Services
HEINZMANN Australia Mini RIO Digital I/O Expansion Module
provides: Expanded remote digital I/O unit for Si-TEC Xtend control (via CAN bus).
User configurable logic inputs and relay outputs for a wide range of
Ruby GSM Utility Grid functions.
Generator Displays Master Display
Remote display of the Si-TEC
Utility Master Displays
Xtend GSM control (via CAN bus
interface). Grid incomer metering
Temperature Displays
of essential parameters. Wide
Temperature Scanners range of GSM alarm displays and
other annunciation.
MPU Speed Sensor Expander
MPU signal isolator with 1-channel input/3-channel output for turbine
I/O Expansion Modules
speed readout. Also includes “failsafe” relay output for MPU signal failure.
Speed Sensor Expanders
TDU Temperature Display
Smart Software &
Diagnostics Remote display of the
temperature scanner (via CAN
bus interface). Display of all

Installations
temperature readings, with
navigation based on either manual
scroll keys or via auto scrolling of Sapphire II Dual Redundant Overspeed Trip
temperature readings.
Precise “overspeed protection” detection for optimum engine safety.
Includes on-line simulation testing & trip valve health monitoring to
verify system functionality and integrity.

8 www.heinzmann.com.au Phone: +61 7 3868 3333 9

 Software & Diagnostics Design & Production

Products
Software Solutions Control system design & production
HEINZMANN Australia delivers smart software for data view, monitoring, configuration and diagnostics of HEINZMANN Australia designs and assembles all generator control systems in-house. The entire process
engine control and generator control systems. including hardware and software design, assembly and testing takes place in our Brisbane premises.
Our qualified team of engineers and state of the art production machines and test equipment ensure reliable
and high quality products.
Configuration Software - pcConfigure
User-friendly configuration for Si-TEC control parameters, along with storage,
retrieval and printing of parameters.
pcConfigure provides the facility to edit all set points, save to PC file,
upload and download to Si-TEC modules, provide hard copy of the Si-TEC
controllers and edit accumulated values. HEINZMANN Australia
provides:
Tuning Software - pcTune
Complete engine and generator control system tuning software, with Entire process including
graphical user interface and intuitive user-friendly functions. design (hardware &

Services
pcTune is a real time tuning and diagnostic tool, providing high-speed data
software), assembly,
and graphic updates, including extensive operating parameters and all PIDs.
Data may be saved, loaded, reviewed, exported, etc.. Additional screens testing, sales, and service
provide instrument panels, dead bus operation, and much more. conducted in-house.

“Ultimate control“ over

Temperature Scanner Software - pcScan quality which guarantees

pcScan is a dedicated program for Si-TEC temperature scanning modules the customer consistently
providing configuration, and real time data graphics for diagnostics. gets a product of
very high quality and
reliability.
Local production area for assembly and testing in the
HEINZMANN Australia facility in Brisbane
100 % testing of all circuit
Logging Software - DataView boards prior to assembly.
DataView is a dedicated data logging and monitoring program developed
specifically for the Si-TEC range of controllers. The system has capability to Test conformance report
support 99 data points for 24 nodes on a 400 msec update rate for all data,

Installations
making it ideal for logging, trending & archiving data. Data can be exported issued to customer.
as CSV (i.e. Excel) file.
Test & calibration
equipment is NIST
Data Hub Gateway accredited
Data Hub allows high-speed Ethernet Modbus TCP/IP communication of (ISO/IEC 17025
up to 8 Si-TEC Xtend control modules simultaneously per Data Hub unit.
compliance). Test and calibration equipment for testing of circuit
Facilitates remote logging, diagnostics and tuning via (ADSL) networks.
boards in-house

For detailed information please refer to product information on www.heinzmann.com.au

10 www.heinzmann.com.au Phone: +61 7 3868 3333 11

 Services

Products
Complete R&D and Qualified & Experienced Team Training
Technical Support Our team are highly trained, many of which have numerous HEINZMANN Australia provides comprehensive training on our
years of hands-on experience over a wide range of products and full product range at our Brisbane facility. Our training packages
HEINZMANN Australia provides a number can also be customised to suit specific client requirements and
applications. We enjoy the opportunity to work with consultants,
of services to support its growing range includes working with our generator system.
authorities and end users in the early stages of system design
of products. We place a high priority to ensure the best possible solution is achieved for any given We also offer on-site training services
on back-up support to our customers application.
including a range of in-house services
and national/international on-site support.

HEINZMANN Australia
provides:

Complete design performed

Services
by our R&D engineers.

Si-TEC Xtend software

developed and tested on
Trouble Shooting ‚ON-LINE‘
simulators and real engines.
Where the optional hardware is installed, we can access the
Generator Application Design controller remotely and provide detailed technical support to
Windows®* software tools HEINZMANN Australia can assist customers and consultants with your site engineers. Detailed product information is available at:
developed in-house. best practice application engineering, and design and integration www.heinzmann.com.au/products/software/data-hub-gateway
of generator control systems to suit specific customer needs. Once
R&D is an on-going effort the operating criteria for the specific application is defined, the Trouble Shooting – Software
control system can be tailored to customer requirements, minimising We have a range of proven software packages which greatly
with continuous focus initial capital costs and providing maximum plant availability, while assist in trouble shooting. Detailed product information is
on development of new reducing maintenance and running costs. available at:
features through valued Power Generation System Design www.heinzmann.com.au/products/software/dataview
feedback & innovative ideas.
Many applications have a range of different generator types. This Retrofit Engineering
may be a mix of prime movers, be it turbines and/or reciprocating
Diagnostics/tuning may be HEINZMANN Australia has successfully designed retrofit

Installations
engine driven generators, alternators of different ratings in the
packages and solutions for many makes of steam turbines, gas
performed remotely via Data active and reactive power capacities, connection to split busses,
turbines, diesel engines and gas engines. In many cases we
multiple parallel utility grid feeders. Combine this with changing
Hub (Ethernet gateway). operating criteria which may be preferred fuelling systems, split bus
manufacture all components in-house in our advanced machine
shop.
system loadings, process control, and process steam requirements.
Secure and quick access, HEINZMANN Australia can assist with design to provide the most Services and Repair
ensuring diagnostics in a suited generator control system for the project.
HEINZMANN Australia provides a complete service and repair
safe controlled environment, facility for all its manufactured products from our Brisbane
and reducing downtime. facility.

* All trademarks are the property of their respective owners.

12 www.heinzmann.com.au Phone: +61 7 3868 3333 13

 Installations

Products
Installation Examples MAN B&W 6.2MVA - 750 RPM EMD 3MVA - 900 RPM
HEINZMANN Australia has more than 4000 Si-TEC Control Systems in operation throughout the world. This includes steam Prime Power Black Start - Sugar Mill
turbine digital governors, generator and grid-parallel controls, hydraulic amplifiers, control accessories and smart software (RioTinto, QLD Australia) (Crystal Sugar, Phillipines)
tools. We cover an extensive range of reciprocating engines used in various applications including mains stand-by, prime Equipped with 6 x HEINZMANN Si-TEC Xtend CGC, Equipped with HEINZMANN Si-TEC Xtend CGC,
power, load curtailment and demand response applications for defence, mining, remote communities, healthcare and Opal II Displays & HEINZMANN StG 64 Actuators Opal II Display & HEINZMANN StG 30 Actuator
mission critical facilities.

MTU 3MVA - 1500 RPM Caterpillar 3.5 M VA - 750 RPM

Mains Stand-by - Healthcare Demand Response, kVarControl - Micro Grid
(Mater Children‘s Hospital, QLD Australia) (Porgera Mine, PNG)
Equipped with 4 x HEINZMANN Si-TEC Xtend Equipped with 6 x HEINZMANN Si-TEC Xtend
CGC, 3 x GSM, Opal II Displays & HEINZMANN CGC, 2 x GSM, Opal II Displays & HEINZMANN
StG 30 Actuators StG 40 Actuators

Services
Deutz 1.6 MVA (1500 RPM)
Co-Generation (Gas) - Water Treatment
(Melbourne Water, VIC Australia)
Equipped with 3 x HEINZMANN Si-TEC Xtend CGC, GSM,
Opal II Displays, HEINZMANN StG 30 Actuators

MAN 14MVA - 500 RPM MIRRLEES 2.5MVA - 500 RPM

Prime Power - Mining Dual Fuel Cogeneration - Water Treatment
(Owen Springs, NT Australia) (Luggage Point, QLD Australia)
Equipped with 3 x Si-TEC Xtend CGC, 1 x GSM, Equipped with 2 x Si-TEC Xtend CGC,
Opal II Displays 1 x GSM, Opal II Displays

Installations
14 www.heinzmann.com.au Phone: +61 7 3868 3333 15
HEINZMANN
Group
Quality & Precision
since 1897

The Group started 1897 with

Heinzmann GmbH & Co. KG,
and now counts
REGULATEURS EUROPA,
HEINZMANN DATA PROCESS
and CPK Automotive
as member companies.

The HEINZMANN Group

Head office Subsidiaries Subsidiaries with production facilities Distributors and dealers
boasts a combined total of
fifteen global subsidiaries,
including eight production
sites and an international
distributor network. HEINZMANN Australia –
Specialists in Steam Turbine and
The product portfolio
comprises engine Engine Generator Controls
management system HEINZMANN Australia are experts on steam turbine and engine generator
controls and have been a member of the HEINZMANN Group since 2014.
solutions, as well as exhaust
gas aftertreatment solutions,
for industrial combustion
engines and turbines; it also
encompasses automation
systems, primarily for the
shipping industry.

Australian Office German Head Office

Heinzmann Australia Pty Ltd Heinzmann GmbH & Co. KG
231 Holt Street (P.O. Box 1413) Am Haselbach 1
Eagle Farm QLD 4009 D-79677 Schönau
Australia Germany
Phone: +61 7 3868 3333 Phone: +49 7673 8208 0
Fax: +61 7 3868 4666 [email protected]
ETM_EGC_001_16_01_e_1_2016

E-Mail: [email protected] www.heinzmann.com

Further representations: www.heinzmann.com/representations

www.heinzmann.com.au