INTRODUCTION GAC s digital governor is designed to regulate engine speed on diesel and gaseous fueled engines. When paired with a GAC actuator the EDG is a suitable upgrade for any mechanical governor system that needs flexibility, precision, or accurate control of governed speed. The EDG is designed for industrial engine applications from generator sets, and mechanical drives, to pumps or compressors. Electronic Digital Governor 3 INSTALLATION Vertical orientation allows for the draining of fluids in moist environments. Mount in a cabinet, engine enclosure, or sealed metal box. Computer SPECIFICATIONS PERFORMANCE Isochronous Operation ± 0.% Speed Range / Governor Idle Adjust Droop Range 400 - KHz Full Range - % regulation Speed Trim Programmable 0-0%, (default = %) Ambient Temperature Supply Polarity Power Consumption Speed Sensor Signal Actuator Load Share / Synchronizer Input Reverse Power Protection Transient Voltage Protection Overspeed Vibration Shock Testing ENVIRONMENTAL INPUT / OUTPUT -4 VDC Battery Systems (. to 33 VDC) Negative Ground (Case Isolated) 70mA max. Continuous Plus Actuator Current 0-0 VRMS MAX Amps Continuous 0- VDC ( V nominal, reversed, 7Hz / V Max) RELIABILITY -40 to 8 C (-40 to 80 F) Relative Humidity up to % All Surface Finishes Internet Connection www.governors-america.com COMPLIANCE / STANDARDS Agency Communications Dimension Weight Mounting PHYSICAL Smart VU Software A computer and an internet connection will be required to download and then run GAC s SmartVU software. CE and RoHS Requirements RS-3-C, SAE J3 See Section 3 Installation oz (70g) Any position, Vertical Preferred Fungus Proof and Corrosion Resistant Yes 0V Rated to A DC 7G, 0-0 Hz 0G Peak 0% Functional Testing 4 4 [.8 ] 00 [ ] 000 WIRING Avoid Extreme Heat 77 [ 7.7 88 ] 8 [ 40 ] [ 8 ].37 4 pin AMPSEAL requires GAC mating connector EC0 or cable harness CH0 [mm] Dimensions: in * Keep reading for diagrams and/or additional notes PIN DEFINITION GAUGE S Actuator (+) # AWG Actuator (-) # AWG Polarity not required for actuator 3 Magnetic Pickup (+) #0 AWG * Ground to Terminal 4 Aux Input #0 AWG * 0 - V Range, V Nominal, Reverse Polarity Speed Select A #0 AWG * Ground to Enable Speed Select B #0 AWG * Ground to Enable 7 RS-3 Enable #0 AWG * Connect to ground to enable RS3 8 Overspeed Output # AWG * A Max Variable Speed Input #0 AWG Ground / Battery Pwr (-) / Magnetic Pickup (-) # AWG Battery Power (+) # AWG CAN Termination #0 AWG 3 (CAN H / RS3 TX) #0 AWG 4 (CAN L / RS3 RX) #0 AWG RECOMMENDATIONS * K Ω Resistive or 0- VDC selectable in software Battery Twisted Pair to Magnetic Speed Pickup A amp fuse must be installed in the positive battery lead to protect against any overload or short circuit * 0 Ohm Resistor Built-In, Jumper to CAN L #4 * Twist Wires 4 turns per foot. Shielded cable should be used for all external connections to the EDG control. One end of each shield, including the speed sensor shield, should be grounded to a single point on the EDG case. Electronic Digital Governor. PIB 44 E
EDG Mating Connector Basic Wiring 4 Magnetic Speed Pick-Up 3 8 7 4 3 + - Fuse AMP Max - + Actuator - Battery + /4 VDC PIN Variable Speed Variable speed is enabled when Terminals and are not grounded. See WIRING COM- BINATIONS. A K potentiometer or a 0- VDC signal can be connected to terminal. Variable Speed can be used as a fixed speed setting if both SPEED MIN and SPEED MAX parameters are set to the same RPM and no potentiometer is connected. See section for Variable Speed Setup Procedure. 0 - VDC Signal K Potentiometer PIN 3 Magnetic Speed Pickup PIN 3 & 4 CAN or RS3 Wires must be twisted and/or shielded for their entire length (4 turns per foot) Gap between speed sensor and gear teeth should not be smaller than 0.0 in. (.mm) Speed sensor voltage should be at least VAC RMS during crank If the detects no input from the magnetic pickup, WARNING the EDG will set the actuator to 0V and set the speed to 0 RPM. After the EDG has detected loss of magnetic pickup, the LED # will flash red and the system must be reset. To reset the EDG, DC power must be cycled. If CAN termination is required, tie pin to pin See CAN WIRING below. CAN WIRING CAN 0 Ohm 7 3 4 Open RS3 WIRING 7 3 4 Tx Rx PIN 4 Accessory Input Case 4 3 The Aux Terminal accepts signals from: GAC Accessories connect directly to this terminal Auto Synchronizers Load Sharing Units Aux Other Governing Accessories Case 4 CAN H CAN L = optional CAN termination 8 7 DB Connector RS3 Enable to ground in order to commuicate (Pin 7). On CANbus there is only engine speed output. It can not take speed requests. The ECU ID is on the CANbus with message EEC Serial cable must be of straight-through type (common), and NOT of null modem/crossover type (uncommon). PIN & Open Terminals PIN 8 Speed Select Grounded Terminals Overspeed Output WIRING COMBINATIONS PIN PIN Speed Mode Open Open Variable Speed (or Fixed Speed) Ground Open Fixed Speed Open Ground Fixed Speed Ground Ground Fixed Speed 3 - Idle Setup of these speed modes will be reffered to in section. If the detects the engine speed has reached the WARNING value specified by OVERSPEED parameter (Main Menu), the will command the engine speed to 0 RPM and the actuator output to 0V. After the EDG has detected an overspeed, LED # will flash and the system must be reset. To reset the EDG, DC power must be cycled. LED DEFINITIONS LED # COLOR DEFINITION FLASHING GREEN Controller is powered and the microprocessor is initialized. FLASHING RED Controller has tripped overspeed. SOLID GREEN Controller has achieved the chosen running speed. FLASHING RED ALTERNATING RED & GREEN SOLID GREEN SOLID RED SOLID AMBER Will pulse when the controller has not reached running speed. Variable speed enabled and controller has achieved the chosen running speed. SPEED Select is enabled and controller has achieved the chosen running speed. SPEED Select is enabled and controller has achieved the chosen running speed. SPEED Select & is enabled and controller has achieved the chosen running speed. LED LED Electronic Digital Governor. PIB 44 E
SMARTVU The is programmed using GAC s SmartVU software. The SmartVU installation file and instructions can be found at: http://www.governors-america.com/downloads/smartvu Setup Connection Menu If your PC only has a USB and no serial port, you need an adapter. You also need to find which COM port will communicate with the EDG. A tutorial on how to find your COM port can be found here: http://www.governors-america.com/downloads/software/pib_comport. After the has been properly selected from the Setup Connection Submenu and SmartVU recognizes the device, parameters can then be adjusted using the Main Menu and the Governor Advanced Settings Menu. Pin 7 on the EDG must be grounded for communication to SmartVU. 7 PRE-START The following parameters must be set before starting the engine: Setup & Safety Overspeed Teeth Ramp Up Ramp Down Starting Parameters Crank Cutoff Actuator Ramp Rate Actuator Begin Point For more details on these parameters, refer to Section Main Menu Parameters 8 STARTING THE ENGINE Crank the engine with DC power applied to the governor system. The initial amount of power to the actuator is determined by the ACTUATOR BEGIN POINT parameter (default is 0% open). ACTUATOR RAMP RATE will control the rate at which fuel is increased to start the engine. ADJUSTING FOR STABILITY Once the engine is running at operating speed and at no load, the following governor performance adjustment can be made to increase engine stability. Setup Connection menu is found under the Configure pull-down menu. PARAMETER MAIN MENU ADJUSTMENT PROCEDURE Increase this parameter until instability develops. Main Menu P (GAIN) I (STABILITY) D (DEADTIME) Then, gradually decrease this parameter until stability returns. Finally, decrease this parameter one increment further to ensure stable performance. If instability persists, adjust the stability parameter. Follow the same adjustment procedure as the P parameter. If instability persists, adjust the deadtime parameter. Follow the same adjustment procedure as the P parameter. P, I, & D parameter adjustments may require minor changes after engine load is applied. Normally, adjustments made at no load achieve satisfactory performance. If further performance improvements are required, refer to Section () GOVERNOR ADVANCED SETTINGS and Section () SYSTEM TROUBLESHOOTING. For more details on these parameters, refer to Section GOVER- NOR ADVANCED SETTINGS. Click Save Data to Device to update governor s memory. 3 Electronic Digital Governor. PIB 44 E
MAIN MENU PARAMETERS Remember to save. Click Save Data to Device to update governor s memory. FIXED SPEED PARAMETERS Speed,,3 0-00,800,00 EDG selects one of three fixed speeds. Fixed Speed 3 is Idle Speed (RPM) Idle speed must be set below operation speed but above crank termination (00-00) even if it is not being used. VARIABLE SPEED PARAMETERS Speed Min 0-00 Minimum allowed RPM desired Speed Max 0-00 Maximum allowed RPM desired STARTING PARAMETERS Crank Cutoff 0-00 480 Actuator Ramp Rate 0-0 Actuator Begin Point 0-0 0 RPM at which EDG switches from starting to governing Throttle position s rate of change from the throttle begin point to 0%, during the start/crank cycle (% / s) Starting position of the actuator during the start/crank cycle (%) Perform the following precedure with the unit powered and the CAUTION engine not running to set the variable speed limits. The potentiometers must be calibrated to those limits afterwards. Variable Speed Setup Procedure In the [3 - Idle Speed] parameter under FIXED SPEED PARAMETERS, input a value 0 RPM below the desired idle speed setting. Navigate to the Governor Advanced Settings menu by clicking on the Options drop-down menu and selecting Governor Advanced Settings. SETUP & SAFETY Overspeed Cust. Dep. 0 Teeth 0-0 0 Ramp Up 0-300 Ramp Down 0-300 RPM at which to automatically shut off the actuator Number of teeth on flywheel [freq(hz) = (RPM/0) x (# of gear teeth)] Allows for rapid engine speed response with minimal overshoot during engine start and acceleration (RPM/s) Allows for rapid engine speed response with minimal undershoot during engine deceleration (RPM/s) Select/enable the check box labeled Variable Speed Voltage. 4 Electronic Digital Governor. PIB 44 E
Return to the main page. Under VARIABLE SPEED PARAMETERS, input the desired idle RPM in the box labeled Speed min and hit the Enter key. GOVERNOR ADVANCED SETTINGS Governor Advanced Settings will further adjust engine stability and can be accessed through the Options pull-down menu on SmartVU s Main Menu.. Input the desired maximum RPM in the box labeled Speed Max and hit the Enter key. You can set the Speed min and max parameters to the same value with no input on pin and use as a fixed speed switch input. Variable Speed Pot Calibration After setting Speed min and max, set the speed input to its minimum; either 0 volts or turn the potentiometer full counter clockwise. Click the button labeled Speed Pot Calibration and hit enter ( or click the button labeled Save Data to Device ). 8. Set the speed input to its maximum; either volts or turn the potentiometer full clockwise.. Click the button leveled Speed Pot Calibration and hit enter ( or click the button labeled Save Data to Device ) The displayed values under Pot min and Pot max are in counts. When a k potentiometer is used as a variable speed input, the total speed range will be 0 to V, which is equivalent to 0 to counts displayed. When a 0 to V input is used, the full range of 0 to 3 counts will be displayed and the unit will operate at its best resolution. ENGINE RESPONSE PARAMETERS P I 0-0, 0 = Max Gain 0-0, 0 = Longest Time 0 Proportional (P) set point of the PID control 3 Integral (I) set point of the PID control D 0-0 Derivative (D) set point of the PID control Dither 0-0%. 0 = No Dither Fuel Limit 0-0% 0 Adds a high-frequency, low amplitude signal to the actuator to prevent the butterfly valve from sticking in harsh environment Maximum allowable throttle % the system can command UPDATE RATE & PID SCALE Update Rate 4-0 4 Changes the rate at which the PID routine is called.(ms) P Scale 0-0 7 If a PID Scale multiplier is changed I Scale 0-0 7 (e.g. P Scale), the corresponding parameter (e.g. P) will be affected in D Scale 0-0 two ways. See below. PID Multipliers If the multiplier is decreased by, the corresponding parameter will double. If the multiplier is increased by, the corresponding parameter will halve. If Multiple PID (See SPECIAL FUNCTIONS below) is enabled, you can not change the PID scale. Simply disable and re-enable. SPECIAL FUNCTIONS Multiple PID Off, On OFF Enables or disables the multi-pid tables which displays a variable map over full engine speed and actuator duty cycle range. When multiple PID is enabled, the user has the ability to set the gain, stability, and Deadtime at each RPM and commanded actuator duty cycle in a -position (8 speeds by 7 positions with customizable axis values) table using the System Tuning menu. The System Tuning menu can be accessed through the Options drop-down Electronic Digital Governor. PIB 44 E
SPECIAL FUNCTIONS (CONTINUED) Overspeed Normally Open Off, On On Overspeed normally open (Box Checked), output voltage (Pin 8) is a 0 until the overspeed threshold is exceeded, at which point output (Pin 8) goes to battery Voltage. Off: Overspeed normally open (box Unchecked) output voltage (pin 8) is at battery voltage until the overspeed threshold is exceeded, at which point output goes to 0 V. Variable Speed Voltage Off, On Off Selects type of input for variable speed signal. Checked = 0- VDC, Unchecked = K Ohm Potentiometer Take caution when adjusting the up/down arrows on the Engine CAUTION Response Parameters on the Main Menu when multiple PID is enabled since any changes made will be reflected for the specific cell (speed vs. position) on the table and not the entire table itself. When a kω potentiometer is hooked up, you will have a range of 0 - V which is 0 - ADC. With 0 - V input enabled, you can use the full range of 0-3 ADC. AUX Aux Input Enable Off, On Off Enables or disables load sync input. SYSTEM TROUBLE SHOOTING SYSTEM INOPERATIVE If the engine governing system does not function, the fault may be determined by performing the voltage tests described in Steps through Positive (+) and negative (-) refer to meter polarity. Should normal values be indicated during troubleshooting steps, then the fault may be with the actuator or the wiring to the actuator. Tests are performed with battery power on and the engine off, except where noted. See actuator publication for testing procedure on the actuator. STEP 3 WIRES Power (-) & (+) Pick-Up 3 & Ground Actuator & Battery (-) & (+) NORMAL READING Battery Supply Voltage ( or 4V DC) 0 VAC RMS min while cranking 0-0 VDC while cranking PROBABLE CAUSE OF ABNORMAL READING DC battery power not connected. Check for blown fuse Low battery voltage Wiring error Gap between speed sensor and gear teeth too great Check Gap Improper or defective wiring to the speed sensor Resistance between 3 and Ground should be 30 to 00 ohms. See specific mag pickup data for resistance. Defective speed sensor. SPEED parameter set too low Short/open in actuator wiring Defective speed control Defective actuator, see Actuator Troubleshooting INSTABILITY Slow Periodic Non-Periodic INSTABILITY SYMPTOM An irregularity of speed below 3Hz. (Sometimes severe) Erratic Engine Behavior PROBABLE CAUSE OF ABNORMAL READING Decrease the update rate of the controller by decreasing the UPDATE Advanced parameter. (Each time UPDATE is changed, P, I, and D must be re-adjusted. Check fuel system linkage during engine operation for: a. binding b. high friction c. poor linkage Add a small amount of droop. Increasing the P parameter should reduce the instability but not totally correct it. If this is the case, there is most likely a problem with the engine itself. Check for: a. engine mis-firings b. an erratic fuel system c. load changes on the generator set voltage regulator. If unsuccessful in solving instability, contact GAC for assistance. GAC@governors-america.com or call: -43-33-888 70 Silver Street, Agawam, MA 00 USA GAC@governors-america.com www.governors-america.com Electronic Digital Governor. PIB 44 E
UNSATISFACTORY PERFORMANCE SYMPTOM Engine Overspeeds Overspeed shuts down engine after running speed is reached Overspeed shuts down engine before running speed is reached Actuator does not energize fully Engine remains below desired governed speed NORMAL READING Do Not Crank. Apply DC power to the governor system. Manually hold the engine at the desired running speed. Measure the DC voltage between Terminals (-) & (+) on the speed control unit. PROBABLE CAUSE OF ABNORMAL READING After the actuator goes to full fuel, disconnect the speed sensor at Terminal If the actuator is still at full fuel-speed then the control unit is defective. If the actuator is at minimum fuel position and there exists an erroneous position signal, then check speed sensor If the voltage reading is 0 to 0 VDC: a. SPEED parameter set above desired speed b. Defective speed control unit If voltage reading is > 0 VDC then check for: a. actuator binding b. linkage binding If the voltage reading is below 0 VDC: a. Defective speed control unit Check #TEETH parameter. Incorrect number of teeth entered. Examine the SPEED and OVERSPEED operating parameters for the engine Check resistance between Terminals 3 & Ground. Should be 30 to 00 ohms. See specific Magnetic Pick-up data for resistance. SPEED parameter set too high. OVERSPEED set too close to SPEED. Actuator or linkage binding. Speed Control unit defective. OVERSPEED set too low If the speed sensor signal is erroneous, then check the wiring. Measure the voltage at the battery while cranking. If the voltage is less than: a. 7V for a V system, or b. 4V for a 4V system, Then: Check or replace battery. Momentarily connect Terminals and The actuator should move to the full fuel position. Measure the actuator output, Terminals &, while running under governor control. Actuator or battery wiring in error Actuator or linkage binding Defective actuator Fuse opens. Check for short in actuator or harness. If voltage measurement is within VDC of the battery supply voltage level, then fuel control is restricted from reaching full fuel position, possibly due to mechanical governor, carburetor spring, or linkage interference. SPEED parameter set too low 70 Silver Street, Agawam, MA 00 USA GAC@governors-america.com www.governors-america.com 7 Electronic Digital Governor. PIB 44 E