ESD5500E Series
Speed Control Unit
1
2
SPECIFICATIONS
INTRODUCTION
±1% Maximum
The ESD5500E Series are all-electronic devices designed to control engine
speed quickly and precisely in response to transient load changes. The ESD5500E will control a wide variety of engines in an isochronous or droop mode
when connected to a proportional electric actuator and magnetic speed sensor.
The ruggedly built ESD5500E is designed to withstand the engine environment.
Light-Force variations are available.
Idle Adjust CW
60% of Set Speed
MODELS
Idle Adjust CCW
Less than 1200 Hz
Droop Range
1 - 5% regulation
PERFORMANCE
Isochronous Operation
± 0.25% or better
Speed Range / Governor
1 - 7.5 KHz Continuous
Speed Drift with Temperature
Droop Adj. Max. (K-L Jumpered)
400 Hz., ±75 Hz per 1.0 A change
Droop Adj. Min. (K-L Jumpered)
15 Hz., ±75 Hz per 1.0 A change
Speed Trim Range
± 200 Hz
Remote Variable Speed Range
500 - 7.5 KHz
Terminal Sensitivity
J 100 Hz., ±15 Hz/Volt @ 5.0 K Impedance
L 735 Hz., ±60 Hz/Volt @ 65 K Impedance
N 148 Hz., ±10 Hz/Volt @ 1 Meg Impedance
P
10 VDC Supply @ 20 mA Max
Polarity
Negative Ground (Case Isolated)
50mA continuous plus actuator current
Speed Signal Range
1.0-50 VAC
Actuator Current Range
@ 77°F (25°C)
Min. 1.0 A
Max. 10 A
Speed Sensor Signal
1.0 - 120 Volts RMS
ESD5500E
Standard Unit
ESD5520E
Light Force
ESD5522E
Light Force / EFC Forward Acting / Enhanced Droop / Smoke
Limiting
ESD5526E
For Use With T1 & T2 ATB Gas Applications / Anti Windup
ESD5528E
For Use With T3 & T4 ATB Gas Applications / Anti Windup
INSTALLATION & OUTLINE DIAGRAM
Vertical orientation
allows fluids to drain
in moist environments.
12-24 VDC Battery Systems
Transient and Reverse Voltage Protected
Power Consumption
DESCRIPTION
3
INPUT / OUTPUT
DC Supply
PROD. NO.
Avoid Extreme Heat
Mount in a cabinet,
engine enclosure, or
sealed metal box.
RELIABILITY
Vibration
1G @ 20-100 Hz
Testing
100% Functionally Tested
ENVIRONMENTAL
Ambient Temperature
-40° to 85°C (-40 to 180°F)
Relative Humidity
up to 95%
All Surface Finishes
Fungus Proof and Corrosion Resistant
COMPLIANCE / STANDARDS
Agency
CE and RoHS Requirements
PHYSICAL
Dimension
See Wiring Diagram and Outline
Weight
1.2 lb. (0.544 kg)
Mounting
Any position, Vertical Preferred
Dimensions
in
(mm)
ESD5500E Series Speed Control Unit 10.27.15 PIB 1002 D
1
© 2015 Copyright All Rights Reserved
4
6
WIRING
PICK-UP BATTERY
ACTUATOR
A
B
-
+
E
F
C D
GA
DROOP
10V
OUTPUT
IDLE OVERNORS
K
M
The speed control unit governed speed setting is factory set at approximately
engine idle speed.
(1000 Hz.,
sensor signal or 600 RPM) If the engine
ON Speed
C2
C1 OFF
does notLEAD
start,
adjustment ofSOFT
the Speed
potentiometer may be required.
COUPLING
CIRCUIT
AUX MERICA
G H
J
L
GROUND TO CASE
N
P
C
ACCESSORY POWER
SUPPLY
S/N :
ACTUATOR
MAGNETIC
+
ADD JUMPER FOR 12V
BATTERY OR ACTUATOR
CURRENTS ABOVE 5A
MADE IN AGAWAM, MA U.S.A.
CLOSE FOR DROOP
SPEED TRIM
CONTROL - 5K
S1
BATTERY
5.000
DEFINITION
A&B
Actuator (+/-)
CAUTION
5.750
(146)
(146)
5.000
NOTES
(127)
5.000
(127)
#16 AWG (1.3mm sq) or larger wire
ENGINE SPEED CONTROL
COMPONENT. WHEN INSTALLING
OR SERVICING REFER TO
PRODUCT PUBLICATION.
-
Wires must be twisted and/or shielded
PICK-UP
for their entire length
C&D
+
8
SWITCH
1
PROFILE 1.031
SPEED
DROOP
BATTERY
ACTUATOR
Gap
between speed sensor and gear
OVERNORS
teeth should not be smaller
than 0.02 in.
MERICA
OVERNORS
(.51mm)
Magnetic Speed
Pickup
(D is ground)
IDLE
5.750
SEE SPECIFIC ACTUATOR PUBLICATION FOR PROPER
* WIRING
OF ACTUATOR BASED ON BATTERY VOLTAGE
(127)
TERMINAL
SPEED
RAMPING
STARTING
FUEL
CLOSE FOR IDLE
FUSE
15A MAX
COMPENSATION
JUMPER
E2
GOVERNOR SPEED SETTING
The governed speed set
point is increased by
GAIN
E1 clockwise rotation of the
SPEED adjustment control. Remote speed adjustment can be obtained with
an optional 5K Speed Trim Control.
GROUND REFERENCE
CW
5.500
PICK-UP
(140)
_
7
MODEL: ESD5500E
ACCESSORY INPUT
*
OFF
ON
Crank the engine with DC power applied to the governor system. The actuator
will energize toSTABILITY
the maximum fuel position until the engine starts. The governor
system should control the engine at a low idle speed. If the engine is unstable
DEAD TIME
after starting, refer to Section 8 ADJUSTING
E3FOR STABILITY.
ORP. TO CASE
GROUND
SPEED CONTROL UNIT
OPTIONAL ACTUATOR
CABLE SHIELDING TO
MEET CE DIRECTIVE
START THE ENGINE
(26
DROOP
IDLE
10V
ADJUSTING FOR STABILITY
AUX OUTPUT
engine is running at operating speed and at no load, the following
A BGCGADCE F GOnce
Hthe performance
J K adjustments
L M canNbe made
P to increase engine stability.
governor
Speed sensor voltage
needs to be at
A
Ccrank
STABILITY
least 1V AC RMS during
Ø0.266
STABILITY
MERICA
ON
C2
C1 OFF
OFFCIRCUIT ON
C2SOFT COUPLING
C1 LEAD
ON
OFF
SOFT COUPLING
LEAD CIRCUIT
ON
OFF
ORP.
ORP.
SPEED CONTROL UNIT
#16 AWG SPEED
(1.3mmCONTROL
sq) or larger
wire
UNIT
E3
MODEL: ESD5500E
E&F
Battery Power (-/+)
E3
A 15 amp fuse must be installed in the
MODEL:
ESD5500E
S/N
: to protect against
Positive battery
lead
reverse voltage
S/N :
GAIN
GAIN
MADE IN AGAWAM, MA U.S.A.
Battery positive
(+) input is Terminal F
MADE IN AGAWAM, MA U.S.A.
STARTING
Add Jumper for 12V Battery orSTARTING
Actuator FUEL
FUEL
Currents Above 5A
SPEED
IDLE
SPEED
RAMPING STABILITY ADJUSTMENT
IDLE
ACCESSORY POWER
RAMPING
SUPPLY
PARAMETER
PROCEDURE
(127)Speed
Variable
5K Resistive Nominal.
See Section10
CAUTION
ENGINE SPEED CONTROL
COMPONENT. WHEN INSTALLING
Table 1
A.
H
CABLE
SHIELDING
TO
5.000
(127)
MEET CE5.000
DIRECTIVE
J
K&L
M
Droop Select
*
ACTUATOR
Idle Select
CAUTION
GAIN
Active When Closed
- +
+
PICK-UP
PICK-UP
BATTERY
ACTUATOR
Load Sharing
/ Synchronizing, 0-10
BATTERY
VDC
ACTUATOR
Close for Idle
N
Accessory Input
P
Accessory Power 10 Volt Output
Supply
PICK-UP
MAGNETIC
-
ACCESSORY
INPUT
1. Rotate the GAIN adjustment
clockwise
until
instability
SWITCH
SPEEDdevelops.
SPEED
ENGINE SPEED
CONTROLREFER TO
OR SERVICING
COMPONENT. PRODUCT
WHEN INSTALLING
PUBLICATION.
OR SERVICING REFER TO
PRODUCT PUBLICATION.
CW
PROFILE
SWITCH
ADDPROFILE
JUMPER FOR 12V
2. Then, gradually move the adjustment counterclockBATTERY OR ACTUATOR
DROOP
DROOP wise until stability returns.
DROOPCURRENTS ABOVE 5A
IDLE
DROOP
3. Finally, move the
10Vadjustment one division further
IDLE
REFERENCE
counterclockwise
toGROUND
insure stable
performance (270°
AUX
10V OUTPUT
potentiometer).
AUX OUTPUT
4.
CLOSE FOR DROOP
BC
DF
EG
F H
GH
J L
KM
LIf instability
MN
P adjust the next parameter.
A A
BC
DE
J K
N
Ppersists,
B.
RECOMMENDATIONS
STABILITY
Ø0.266
1. Follow the same adjustment procedure,
steps 1 - 3,
as the GAIN parameter.
SPEED TRIM
Ø0.266(6,6)
CONTROL - 5K
IDLE
(6,6)
Normally, adjustments made atCLOSE
no load FOR
achieve
satisfactory
Shielded cable should
for all external connections to the ESD
_ be used
+
S1
control.
NOTE
performance. If further performance improvements are required,
refer to Section (12) SYSTEM TROUBLESHOOTING.
FUSE
BATTERY
One end of each shield,
including the speed sensor shield,
15A should
MAX be
2.
E1
E1
5.500
5.500 (140)
Ground Signal
(140)
OPTIONAL ACTUATOR
G
1.
E2
E2
DEAD TIME
(6,6)
DEADCOMPENSATION
TIME
JUMPER
COMPENSATION
JUMPER
grounded to a single point on the ESD case.
5
*
SEE SPECIFIC
ACTUATOR PUBLICATION FOR PROPER
OPTIONAL
ACTUATOR
ADJUSTMENTS
BEFORE
ENGINE
STARTUP
CABLE
SHIELDING
TO
OPTIONAL
ACTUATOR
WIRING
OF ACTUATOR
BASED ON
BATTERY VOLTAGE
MEET
CE
DIRECTIVE
CABLE
SHIELDING
TO
Make sure
the following
adjustments
are set before starting the engine.
MEET CE DIRECTIVE
GAIN
*
STABILITY
*
Middle Position
Middle Position
ACTUATOR
SPEED
TRIM CONTROL
ACTUATOR
Middle Position
STARTING FUEL
Full CW (Maximum Fuel)
MAGNETIC
SPEED RAMPING
MAGNETIC
PICK-UP Full CCW (Fastest)
PICK-UP
_
_
+
+
S1
BATTERY
BATTERY
*
S1
FUSE
FUSE
15A MAX
15A MAX
CW
CW
SPEED TRIM
CONTROL
- 5K
SPEED
TRIM
CONTROL - 5K
2
SEE SPECIFIC ACTUATOR PUBLICATION FOR PROPER
WIRING OF
ACTUATOR
BASED ON BATTERY
VOLTAGE
SEE SPECIFIC
ACTUATOR
PUBLICATION
FOR PROPER
ACCESSORY POWER
SUPPLYPOWER
ACCESSORY
SUPPLY
ACCESSORY INPUT
ACCESSORY INPUT
ADD JUMPER FOR 12V
BATTERY
OR 12V
ACTUATOR
ADD JUMPER
FOR
CURRENTS
ABOVE 5A
BATTERY
OR ACTUATOR
CURRENTS ABOVE 5A
GROUND REFERENCE
GROUND REFERENCE
CLOSE FOR DROOP
CLOSE FOR DROOP
WD
WD554
CLOSE FOR IDLE
CLOSE FOR IDLE
ESD5500E Series Speed Control Unit 10.27.15 PIB1002 D
© 2015 Copyright All Rights Reserved
5.750
GA
5.000
9
C1 OFF
OVERNORS
MERICA
(146)
(127)
STARTING FUEL
ADJUSTMENT
C
11
ORP.
The engine’s exhaust smoke at start-up can be minimized
completing
the
SPEEDby
CONTROL
UNIT
following adjustments:
5.750
GA
5.000
C 5.500
STABILITY
SPEED CONTROL UNIT (140)
STARTING
DEAD TIME
COMPENSATION
FUEL
Adjust the STARTING FUEL CCW until the engine speedE3begins to fall.
MODEL: ESD5500E
Increase the STARTING
FUEL slightly
so that the idle speed
E2is returned
5.000
ON
RNORS
C2
C1 OFF
to the desired level.
MERICA
S/N
:
SOFT COUPLING
LEAD CIRCUIT
(127)
GAIN
E1
CAUTION
ON
OFF
3.
A C4. Stop the engine.
ORP.
NTROL UNIT
SD5500E
CAUTION
-
-
+
PICK-UP JUMPER
SPEED
RAMPING DROOP
+
IDLE
10VCOUPLING
LEAD CIRCUIT & SOFT
IDLE
switch to the “OFF” position if there is fast instability in the system. Switch 2(C2)
controls a circuit designed to eliminate fast erratic governor behavior, caused by
very soft or worn couplings in the drive train between the engine and
generator.
Ø0.266
The normal position is “OFF.” Move to the “ON” position if fast erratic
engine
(6,6)
behavior due to a soft coupling is experienced
DROOP
10V
PROFILE
C1 OFF
ON
C2
SOFT COUPLING
OFF
LEAD CIRCUIT
METHOD 1
Ø0.266
DROOP
ON
DROOP
-UP Start the engine and accelerate
(6,6)
directly
to SPEED
the operating speed (Generator Sets,
IDLE
10V
BATTERY
etc.).
OPTIONAL
5.750 ACTUATOR
AUX OUTPUT
(146) PROCEDURE
CABLE SHIELDING
TO
DROOP
MEET CE DIRECTIVE
5.000 Terminals M & G.
1.
Remove the connection between(127)
-
+
3.
4.
IDLE
ACCESSORY POWER
SUPPLY
DE F GH J K L MN P
2.
DROOP
A BC DE F GH J K L MN P
B One
C10ofDtwoEmethods
F G
HSPEED
Jfor K
L MN P
of operation
the ESD5500E may now be selected.
ED CONTROL
HEN INSTALLING
NG REFER TO
UBLICATION.
IDLE
AUX OUTPUT
SWITCH
Switch 1(C1) controls the “Lead Circuit”. The normal position is “ON.” Move the
PROFILE
AUX OUTPUT
IDLE
TWO METHODS OF OPERATION
SWITCH
TION
DROOP
BATTERY
SPEED
STARTING
PICK-UP
FUEL
BATTERY
TOR
SWITCH
PROFILE
SPEED
COMPENSATION
E2
IDLE
JUMPER
DEAD TIME
IDLE
E3
ACTUATOR
E1
GAIN
ENGINE SPEED CONTROL
WAM,COMPONENT.
MA U.S.A. WHEN INSTALLING
OR SERVICING REFER TO
PRODUCT PUBLICATION.
SPEED
RAMPING
ENGINE SPEED CONTROL
COMPONENT. WHEN INSTALLING
OR SERVICING REFER TO
PRODUCT PUBLICATION.
MADE IN AGAWAM, MA U.S.A.
STABILITY
SPEED
STARTING
RAMPING
FUEL
STABILITY
DEAD TIME
COMPENSATION
If the IDLE speed setting was not adjusted as detailed in Section 9 “Starting Fuel
E2
JUMPER
Adjustment”, then place the optional external selector switch in the IDLE position.
1.031
E1
The idle speed
set pointGAIN
is increased by the clockwise
rotation of the IDLE adjust(26) the engine is at idle speed, the speed control unit applies droop
ment control. When
to the governor system to insure stable operation.
S/N :
allows.
ADDITIONAL
(26) FEATURES & OPTIONAL WIRING
E3
ON
C2
C1 OFF
1. OVERNORS
Place the engine in idle by connecting
Terminals
M & G.
MERICA
SOFT COUPLING
LEAD CIRCUIT
ON
OFF
AGAWAM, MA U.S.A.
2. AdjustORP.
the IDLE speed for as low a speed setting asMADE
theINapplication
(127)
ON
C2
SOFT COUPLING
1.031 OFF
IDLE SPEED SETTING
ADJUSTMENT PROCEDURE
MODEL: ESD5500E
(146)
LEAD CIRCUIT
ON
*
WD554
Ø0.266
Start the engine and adjust the SPEED RAMPING for the least smoke
on
ACCESSORY
POWER
(6,6)
acceleration from idle to rated speed.
SUPPLY
1.031 SPEEDACCESSORY INPUT
(26)
ADD JUMPER FOR 12V
DROOP
BATTERY OR ACTUATOR
ACTUATOR
CURRENTS ABOVE 5A
ACCESSORY INPUT
ACCESSORY
Start the engine and adjust the SPEED RAMPING for the least
smoke on INPUT
GROUND
REFERENCE
acceleration from idle to rated speed. OFF
ON
OVERNORS
C2 ADD JUMPER FOR 12V
C1
The CW
Auxiliary Terminal N accepts input signals from load sharing units, auto
MERICA
MAGNETIC
SOFT
COUPLING
LEAD CIRCUIT
synchronizers,
accessories,
GAC accessories are
BATTERY
WD554and other governor systemCLOSE
If the starting time is too long, the STARTING
FUEL
may need
to be OR ACTUATOR
ON
FOR DROOP
OFF
PICK-UP
CURRENTS ABOVE 5A
directly connected to this terminal.
ORP. CW.
adjusted slightly
GA
C
SPEED CONTROL UNIT
_
MODEL: ESD5500E
S/N :
STABILITY
CW
+
SPEEDBATTERY
TRIM
CONTROL - 5K
MADE IN AGAWAM, MA U.S.A.
S1
ACCESSORY POWER
GROUND REFERENCE
SUPPLY
E3 DROOP
ACCESSORY
CLOSE INPUT
FOR
E2
ADD JUMPER
FOR 12V
FUSE
BATTERY15A
OR ACTUATOR
GAIN
E1
MAX
CLOSE
FOR5A
IDLE
CURRENTS
ABOVE
NOTE TRIM
SPEED
Terminal N is sensitive. Accessory connections must be shielded.
DEAD TIME
CONTROL
- 5K
CLOSE FOR IDLE
COMPENSATION
When an accessory is connected to Terminal N, the speed will decrease and the
JUMPER
speed adjustment must be reset.
When operating in the upper end of the control unit frequency range, a jumper
*
GROUND
REFERENCE
SEE SPECIFIC ACTUATOR
PUBLICATION
FOR PROPER wire or frequency trim control may be required between Terminals G and J. This
CW
FUSE
WIRING OF ACTUATOR
BASED ON BATTERY VOLTAGE increases the frequency range of the speed control to over 7000 Hz.
SPEED
15A MAX
STARTING
IDLE
CLOSE FOR DROOP
RAMPING
FUEL
PUBLICATION FOR PROPER
SED ON BATTERY VOLTAGE
SPEED TRIM
CAUTION
CONTROL - 5K
METHOD 2
If the auto synchronizer is used alone, not in conjunction with a load sharing module,
a 3 ohm resister should be connected between Terminals N and P. This is required
to match the voltage levels between the speed control unit and the synchronizer.
CLOSE FOR IDLE
SWITCH
PROFILE
ENGINE
SPEED CONTROL
Start
the engine
and maintain at an idle speed for
a period of time prior to accelCOMPONENT. WHEN INSTALLING
SPEED
OR SERVICING
TO
to the REFER
operating
speed. This method separates the starting process so
USE erating
PRODUCT PUBLICATION.
that each may be optimized for the lowest smoke emissions.
A MAX
PICK-UP
-
+
PROCEDUREDROOP
ON FOR PROPER
IDLE
10V
CTUATOR
TTERY
1.VOLTAGE
Replace the BATTERY
connection between Terminals M & G with a toggle switch
DROOPThe +10 volt regulated supply, Terminal P, can be utilized to provide power to
GAC governor system accessories. Up to 20 mA of current can be drawn from
this supply. Ground reference is Terminal G.
AUX OUTPUT
or a normally open water jacket temperature switch. Other optical switch
combinations can be used.
A BC DE F GH J K L MN P
2.
Start the engine.
3.
If the starting smoke is excessive, the STARTING FUEL may need to be
adjusted slightly CCW.
4.
5.
Accessory Supply
CAUTION
A short circuit on this terminal can damage the speed control unit.
Ø0.266
(6,6)
If the starting time is too long, the STARTING FUEL may need to be
adjusted slightly CW.
When the switch opens, adjust the SPEED RAMPING for the least
amount of smoke when accelerating from idle speed to rated speed.
WD554
ACCESSORY POWER
SUPPLY
ACCESSORY INPUT
3
ADD JUMPER FOR 12V
BATTERY OR ACTUATOR
ESD5500E Series Speed Control Unit 10.27.15 PIB1002E D
© 2015 Copyright All Rights Reserved
LE
POTENTIOMETER WIRING
WIDE RANGE REMOTE VARIABLE SPEED OPERATION
G
A single remote speed adjustment potentiometer can be used to adjust the engine
speed continuously over a specific speed range.
Select the desired speed range and corresponding potentiometer value. (Refer to
TABLE 1 below) If the exact range cannot be found, select the next higher range
potentiometer.
* Select proper potentiometer
value from Table 1
The ESD5000 series of controllers have the ability to expand the
speed range by placing a jumper wire across terminals G and J.
The standard range is 7400 Hz however this is based on the operating speed
and the number of flywheel teeth (see formula). If you application is above this
frequency, or near it – place the jumper and test again. This is an important step
if your engine is not able to reach rated speed but the actuator is not saturated.
NOTE
An additional fixed resistor may be placed across the potentiometer to obtain the exact desired range. Connect the speed range
potentiometer as shown to the right using Terminals G and J. Contact GAC for
assistance if difficulty is experienced in obtaining the desired variable speed
governing performance.
SPEED DROOP OPERATION
TABLE 1
POTENTIOMETER VALUE
1K
2400 Hz
5K
3000 Hz
10 K
3500 Hz
25 K
3700 Hz
50 K
Conversion Formulas
HertzMAG PICKUP =
12
(RPM x #Teeth)
60sec
RPM =
L
CW
NOTE
900 Hz
K
*
To maintain engine stability at the minimum speed setting, a small amount of
droop can be added using the DROOP adjustment. At the maximum speed setting the governor performance will be near isochronous, regardless of the droop
adjustment setting.
SPEED FREQUENCY RANGE
J
Droop is typically used for the paralleling of engine driven generators. When in
droop operation, the engine speed will decrease as engine load increases. The
percentage of droop is based on the actuator current change from no engine
load to full load.
Place the optional external selector switch in the DROOP position. DROOP is
increased by clockwise rotation of the DROOP adjustment control.
After the droop level has been adjusted, the rated engine speed setting may
need to be reset. Check the engines speed and adjust that speed setting accordingly.
(HertzMAG PICKUP x 60sec)
Though a wide range of droop is available with the internal control,
droop level requirements of 10% are unusual. If droop levels experienced are higher or lower than those required, contact GAC for assistance.
NOTE
#Teeth
TROUBLESHOOTING
If the engine governing system does not function, the fault may be determined by performing the voltage tests described in Steps 1 through 4. Positive (+) and negative (-) refer to meter polarity. Should normal values be indicated during troubleshooting steps, and 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.
SYSTEM INOPERATIVE
STEP
1
WIRES
NORMAL READING
F(+) & E(-)
Battery Supply
Voltage
(12 or 24 VDC)
PROBABLE CAUSE OF ABNORMAL READING
1. DC battery power not connected. Check for blown fuse.
2. Low battery voltage
3. Wiring error
1. Gap between speed sensor and gear teeth too great. Check Gap.
2
C(+) & D(-)
1.0 VAC RMS min.
while cranking
2. Improper or defective wiring to the speed sensor. Resistance between D and C should be 160 to 1200 ohms.
See specific mag pickup data for resistance.
3. Defective speed sensor.
3
P(+) & G(-)
10 VDC, Internal
Supply
1. Short on Terminal P.
2. Defective speed control unit.
1. SPEED parameter set too low
4
F(+) & A(-)
1.0 - 2.0 VDC while
cranking
2. Short/open in actuator wiring
3. Defective speed control
4. Defective actuator, see Actuator Troubleshooting
4
ESD5500E Series Speed Control Unit 10.27.15 PIB1002E D
© 2015 Copyright All Rights Reserved
INSTABILITY
INSTABILITY
SYMPTOM
Fast Periodic
The engine seems
to jitter with a 3Hz or
faster irregularity of
speed.
An irregularity of
speed below 3Hz.
Slow Periodic
PROBABLE CAUSE OF
ABNORMAL READING
1.
Make sure switch C1 is set to “OFF”.
2.
Readjust the GAIN and STABILITY for optimum control.
3.
Remove the E1 to E2 jumper. Readjust GAIN and Stability afterward.
4.
Turn off other electrical equipment that may be causing interference.
1.
Readjust the GAIN and STABILITY
2.
Adjust the DEAD TIME COMPENSATION by adding a capacitor from posts E2 to E3 (negative on E2).
Start with 10 mfds. and increase until instability is eliminated.
3.
Check fuel system linkage during engine operation for:
a. binding
b. high friction
c. poor linkage
1.
Increasing the GAIN 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.
2.
If throttle is slightly erratic, but performance is fast, then move switch C1 to the “OFF” position.
Erratic Engine Behavior
Non-Periodic
UNSATISFACTORY PERFORMANCE
SYMPTOM
NORMAL READING
1.
Engine
Overspeeds
Actuator does not
energize fully
Engine remains
below desired
governed speed
Do Not Crank. Apply
DC power to the governor system.
Manually hold the
engine at the desired
running speed. Measure the DC voltage
2. between
Terminals A(-)
& F(+) on the speed
control unit.
PROBABLE CAUSE OF ABNORMAL READING
1.
After the actuator goes to full fuel, disconnect the speed sensor at Terminal C & D. If the actuator is still at
full fuel-speed then the speed control unit is defective.
2.
If the actuator is at minimum fuel position and there exists an erroneous position signal, then check speed
sensor cable.
1.
If the voltage reading is 1.0 to 1.5 VDC:
a. SPEED adjustment is set above desired speed
b. Defective speed control unit
2.
If voltage reading is above 1.5 VDC then check for:
a. actuator binding
b. linkage binding
3.
If the voltage reading is below 0.8 VDC:
a. Defective speed control unit
1.
Measure the voltage
at the battery while
cranking.
1.
If the voltage is less than:
a. 7V for a 12V system, or
b. 14V for a 24V system, Then: Check or replace battery.
Momentarily connect
Terminals A and F. The
actuator should move
to the full fuel position.
1.
Actuator or battery wiring in error
2.
2.
Actuator or linkage binding
3.
Defective actuator
Measure frequency of
3. magnetic speed pickup
(or calculate).
1.
If above 7000 Hz then add jumper to terminal G and J.
1.
If voltage measurement is within 2 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.
2.
SPEED parameter set too low
1.
Measure the actuator
output, Terminals A &
B, while running under
governor control.
INSUFFICIENT MAGNETIC SPEED SIGNAL
A strong magnetic speed sensor signal will eliminate the possibility of missed or extra pulses. The speed control unit will govern well with 1.0 volts RMS speed sensor
signal. A speed sensor signal of 3 VAC or greater at governed speed is recommended. Measurement of the signal is made at Terminals C and D.
The amplitude of the speed sensor signal can be raised by reducing the gap between the speed sensor tip and the engine ring gear. The gap should not be any smaller than 0.020 in (0.45 mm). When the engine is stopped, back the speed sensor out by 3/4 turn after touching the ring gear tooth to achieve a satisfactory air gap.
5
ESD5500E Series Speed Control Unit 10.27.15 PIB1002E D
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