ESD5500E User Manual Ver 1.0 Date: 2013/05/08 ESDS5500E SERIES SPEED CONTROL UNIT Software Version Date | Version | Note 2013-05-08 | 1.0 | OriginalreleaseESD5500E SERIES SPEED CONTROL UNIT INTRODUCTION ‘The ESDSSO0E Sue ped contol tis na eectonic ice designed cant engine sped wih es and pei ‘esposeto tans bd changes. This cased ep canto, han connected a roporoal sect cual nd sup lod wih a magne seed sersr sta wl etl a wee ‘ois of engine inn soeronaus a oop mado tis eign orig ebily andl ged twist the ‘engine environment Simply oinstalain and adusinent nas frost inte design Now-nrocing psomsnce cont alow nea pt ‘mum response fo be easy obtained. The pinay feats the ESDSSONE Series speed esto! Ut ate enge STARTING FUEL ad SPEED RAMPING ‘jst. These ofthese features wil inimize engine ‘aus smoke exprenced prion atairg eng opt ing speed (tne furs inte austate crop andi operation, inputs acessories sed nul or speci api tons, pretecton apa verse baer ota, reset scodeil har crate cut nd al ale asin evet of os of ped sensor sgl orbatry supp ‘The ESOSSOE Series speed conta uns compat wi at {GAC proportional actuators except the ACB2000 electric ‘azuat When Se ESDSSOVE Sees spee carl tits ‘sed wih a ADCT0O Series electric actuator, the DROOP _ausimertrange i be ess dv to ths actors nw cue demand, DESCRIPTION Engi speed infraton fr te spend cate unt sly received rom a magnetic speed Sensor. Ary oer signal geaig device may be used proved the generated fe {enc pozortonal in engne sped and ees volane puted equncy ange specicaton. The sed sesors "yay outed in cose pouty oan engine ve fous {ear usualy erie rig ea. Ashe ah cf gear pass The magnet sensor, signals great wich is propor onal engine speed ‘Sia rengh must wii the range of hemp si. Anampltude of 05 1 20 as AMS sequel alow he tuts uncon wit ts dosgn specications. The speed Signals ppsta Temas Can D of spedconal unit Between ese eminl ee an nu impedance foe" ‘3,000 ohns. Terminals intra comected a Terminal tener nga. Only eer ofthe shed abe stud be comectes When 2 speed sansa gas raced ty he conte, te ‘igalis apes ar sheped yan inter cxuto povite ‘andy speed sina. the speed sersr mont does ot Chet a spe ero sgn, ouput ct oh speed ‘ont! unt wil um of al curent othe actuator. BRODUCT TECHNICAL INFORMATION ~ summing cout receives the speed sensor signal along wth ‘the speed adjust et pom np Te speed range as @rato ‘oft andi adjusted wih a 25 tum potentiometer. The ouput ‘fom the summing cutis the put othe dynamic conto. secon ofthe speesconl un. Te dyramic contol eu, af wich the gan and stabiny adjustments are part has 2 onl uncon that wl provide sctronous and table pe. formance for most engine ypes and ue systems ‘The speed contol unitccutisinfuenced bythe gain and sSably perfomance adjustments. The governor sytem sen- ‘tity is nereaeee wth clocisertalon ofthe gan ach ‘ment The gain adjustment has a range of 31, The saity ‘adjustment when advanced clockwse, increases he time rate of response ofthe governor ystom fo match the various time constants ofa wide variety of engines. The speed conte Untis a ID dei, the", derivative porton canbe varied > when equied, (See instabity secon) ‘uring the engine cranking cycle, STARTING FUEL can be ‘adjusted from an almost cose, to 8 ner ul fue poston ‘Once the engine has started, the speed conitl pts ‘eteminad ist by te IDLE speed set point andthe SPEED RAMPING crest. Aer engine speed ramping hasbeen complete, he engi willbe atts governed operating speed ‘Althe deed governed engine speed, the acute willbe ‘enerpiznd with suficent curento mainian the desired er- ‘gin speed, independent ood eochranaus operation) “The ouput cult provides switching ourentat fequency of out $00 He. crv tho actuator. Since the switching frequency s well beyond the nual equency of he ectuator, there iso visible mason ofthe actuator output shat. Switch ing the out transistors reduces its intemal power dissipation fot efcient power contol Te ouput ccut can provide stent of upto 10 amps continuous 225°C for 12 and 24 VOC. bat systems. The actuator responds tothe average cunt to poston the engine fel coro eve. In standard operaton, the speed contol unt perfomance Isochronous. Droop governing canbe slected by connecting terminals K and Land the perent of droop governing canbe ‘varied wit the droop adjustment contol The droop range can be decreased by conecng Terminale Gand ‘The speed contol unithas several perfomance and protc- tion features wich enhance the governor system. A speed antcpaton cult miniizes speed overshoot on engine star Gp or when are ivements of aad ae app othe engine. Engine ic speed canbe remotely slected and i adjustable, ‘Accontry input achieve varie speed operation and ‘mul-engine contol canbe accepted by the ESDSEQOE Sis ‘peed contol un am GAC load sharing madues, automatic ‘ynetronizrs, ramp generators and other acoessar engine ‘contol medules. Protection against reverse bate votage ‘and wandiont voages is provided. The design is falsae nthe ‘event of lasso speed sensor signal or batery supply.ESD5500E SERIES SPEED CONTROL UNITS ‘SPECIFICATIONS PERFORMANCE, Iscchronous Operaton’teady State Stability £0.25% or beter Speed Range!Goveror 7 17 5K He continuous Speed Ox wih Temperature = 21% Maximum Ide Aj CW 6% of st speed le jst. CoW. Lessthan 1200 reop Range 1-5% regulation” Droop Adj Max. (K Jmpered) 400 H.,=75 Hz per. Ackange ‘Droop Adj Min (KL Jumpered) 15H, 6 Hz pr .OAchange ‘Speed Ten Range ne 200 HE Remate Vaietle Speed Range 500-75 He orany pat thereat Terminal Sensitivity J 100 He, +15 He Vt @ 5.0 impedance L 735 Hz, = 0 He/ Val @ 65 K Impedance N “WB He. 10 He Vol @ 1 Meg. Impedance P 10V0C Supply @ 20 ma Max. ENVIRONMENTAL or ‘Ambient Operating Temperature Range 401 F180 F (40't0 288°C) lave Hurity| up o5% [AU Sutace Fishes Fungus Prot and Corsion Resistant INPUT POWER suey 120r24 VDC Batter Systoms (Transient and Reverse Voltage Protected” Play Negative Ground (Case Isolated) Power Consumption ‘50 me continuous pls actuator cuent ‘Actuator Curent Range @ 77°F (25°C) -(inovetve Load) Min. 25 Amps... Max. 10 Amps continuous™* Speed Sensor Signal (05-120 Vots RMS RELIABILITY irate 16.9 201004 “Testng eae "00% Funetonay Tested PHYSICAL Dimension. oe Outine (FIGURE 1) Weigh 1.21 (545 gas) Mounting ‘ay Posto, Verial Prefered “Droop is based ona speed sensor frequency of 4000 Hz. and an actuator curentchange of 1 amp from no load to ulead, Appeations wih higher speed sensor signals wil experince lss percentage of crop. Aplications wth more actuator curent change wl experence higher perceriages of droop. See droop description fr spect ‘elas on operation of oop ranges. When uses wh the ADC100 actuator the coop percerage wil be less due tothe acuaterslow curent consumetion “Pretected against reverse volage by a series diode. A 18 amp fuse must be installed inthe postive battery less. “Protected against shot Gru o actuator shuts of cunt to actuatr, uni automaticaly tums back on when short is moved acm [-] esos i on re | ttn s oh < exrernat SPEED seen Sees thwe Tor ORGOF ue eee oT ax Sreut | ABC DEFGHJKLMNP || 98 ish Va 26 .6nm tO} f o conan auneR eee LN U po mame acrusron_| ane ‘pecur <—}—~ ye) | Lb et poemnee {eH | Bit [Lt tens BATTERY ca APPLICATION AND INSTALLATION INFORMATION ‘Te speed contol units aged enh te laced in 2 Conroe eng mated ences whe Oe Catd conta eupnet wae, mst. arene may Come m conte wie conrl, shouldbe outed ‘eral Tas loon be hadron oy foe seed ‘Stem at shouldbe avoies WARNING An overspeed shutdown device, ependnt of the ‘governor system, should be provided to prevent ss of engin control which may cause personal injury or ‘euipment damage. Do not rely exclusively onthe {governor system ect actual o prevent overspeed ‘Asocondary shutoff devioe, such asa fel solenoid mus bo used.‘ WIRING Basic electal connections sr ilustrated in Dagram 1 Actuator nd batery connections to Terminal A,B, and F should be #16 AWG (13 mm sq) orlarger Long cables require an increases wie size 0 miniize otage cops The batey postive (+ input, Terminal F, should be fused for ‘Soamps as states. Magnetic speed sensor connection to Terminals and 0 MUST BE TWISTED ANDIOR SHIELDED fr haere length. The speed sensor cable shel shou be ideally ‘connected to trinalD. The shield shoul be nested to Insure no other part of the shied comes in contact with engine (rund, cerwise stay speed signs may be invoice 0 {he speed contol unt. Wh the engine stoped, adjust he gap between the magnetic sped sensor ad the ring gear tet, ‘The gap shoud not be any smal than 0020 i. (045 rm), Usualy, backing etthe speed sensor 3 tum ater touching the ring ger oth wl achieve a sattacory sic gap. The magnet speed sensor wotage shoul beat last 1 VAC RMS ‘ug eranking ADJUSTMENTS: ‘Before Staring Engine Check o insur the GAIN na STABILITY asustments, and if ope, the extenel SPEED TRIM CONTROL ae sto mid poston. Prest he ESDSSOOE as falls: ‘STARTING FUEL FULL CW (Maximum Fue) ‘SPEED RAMPING. FULL CCW (Fastest) Star Engine ‘Tre speed cons nit gover pee ang iat ett spprcemataly erin ie speed. (1000 He, peed sensor signa) Crank he engine wth OC power appli othe governor system. The acuater wll energize tthe maximum fel poston unl he eng stars, The gover ssi soul ‘canel te engne at lw ide see. th engines urstble er tarbg, tum te GAN and STABILITY ajstnents counterclockwise unl the engine is stable Governor Speed Seting ‘The governed speed set points increased by clockwise ‘oaton ofthe SPEED adusert conte mate speed jst canbe tied witha loa Sped Tim Control. (See Diagram 1) Governor Performance Once the engines at aerating speed and at alae, the ‘alonng gover peemance asnent canbe mace, ‘A Rotate the GAIN adjustment clockwise unl intabity eves, Geta rove eager counecckwise ul sity res. Move essen one dist ater ‘oumircockwieto insure sable perfomance, 8. Rotate the STABILITY adjustment clockwise unt inti ty develops. Gradually move the adjustment conterceck- Wise unt stably tums. Move the ajustment one dision further to insure sabe perormance. ©, Gain and stabity ajustrenss may require minor changes sifer engieoad is applies. Normally, agjstments mage at no lood active satisfactory perfomance A stp chart recorder can be used tourer optima the adjustments. IFnstabity cannot be corected or further performance im provements ar required, oer to the secton on SYSTEM ‘TROUBLESHOOTING ‘Stating Fuel Adjustment “The engine's exhaust smoke at start-up can be minimize by completing he folowing acustment, 1, Place the engine in dle by connecting Terminals M & G 2. Adjust the IDLE speed for a low a speed setting asthe ‘pplication allows. 2. Adjst he STARTING FUEL CCW until he engine speed begins fal Increase the STARTING FUEL sight so hat the de speeds retuned othe dese level. 4. Stop the engine. ‘ne of wo methods of operation forthe ESOSSOOE may row be select, Matix t: Sian the engine and acelrate dct tthe ‘peraing speed (Gen Sets, et). Method 2: Stat the engine and contol tan ide speed fora ero of ime prior to accelerating othe operating speed. This ‘meth sepastes the staring process so that each maybe optimizes for the lowest smoke emissions, Method 1 Remove the connection betwoon Terminals M &G. Stan the ‘engine and aust he SPEED RAMPING othe least smoke ‘on acceleration fom le orate speed. I the staring smoke is excessive, he STARTING FUEL may ned tbe adjusted ‘sighty CCW the staring tne i to long, the STARTING FUEL may need tobe adjusted shy CW Metiod 2 Replace the conection between Terminals M8 G wih 2 sich, usualy an ol pressure switch, Sat he engine the Stating sok is excessive, the STARTING FUEL may need tobe adste sighty COW. the starting time too lng, the STARTING FUEL may need tobe adjusted shy CW. ‘nen the swtch opens, east amount of smoke ‘ated spoed st tne SPEED RAMPING forthe; ce Speed Seting ‘Wine IDLE speed setng wos not sgusted as deed in “Staring Fuel Adjustment section, hen place the optional ‘extemal selector suite nthe IDLE postion. Th de speed Set pontis increased by clockise rotation ofthe [DLE adjustment contol When the eng is tile speed, the ‘speed contol unt apes droop othe governor sytem to Insure stable peraton. ‘Speed Droop Operation Droop typical sed forthe paling of engine ven generators, Place the optional extemal selector tc nthe DROOP poston, DROOP is ncreased by clockwise rotation ofthe [ROO ausrent corr When in sfeop operation, he engine speed wil decrease as engine load increases. The percentage of droop is based on the acuator curent change ‘rom engine no load ofl load. A wie ange drop is avaiable wi the nial onl. Drop level requirements ‘hove 10% are unusual. 1 éoop loves experienced ar higher or lower than hose requred, contact he acta for assistance. _Aterth cop evel has been aust the ates engine Speed setng may need tobe reset. Check he engine speed and adjust the speed sting accoinly. ‘Accessory Inout ‘The AUK Terminal N coop input sina rom oad sharing unts, ute synchronizes, and cher govemor sytem accessories, GAC arcessores are dec conrecedt his terminalis recommended tat his connection fom acces: Sores be sheded as tsa sensi put temina, rte auto synchronizer used aloe, notin conjunction with ‘sloed sharing module, 23M ohm esisor shoul be co ‘ected betwoen TeminasN and P. This req to match ‘he votagelves between te speed conrl uit ar he sychronar. nen an accessory is conncted to TeminlN thes wl decrease andthe speed ecustent must be est \en operating inthe uoper end ofthe coal unt requency range, ump eo requency tin carol may be requ between Terminals G and J This increases the equency range ofthe speed conte! to ovr O00 He Accessory Supply ‘The +10 vores spy, Terminal, an be aed o roe pono GAC gov aystam cress Upto 2 ‘a olcarentcanbe dam or hs spy, Goud elec 's Tein! G. Caudle: 2 shor cxuton is emia can erage the speed contol un. Wide Range Rermte Versble Speed Operation ‘Simpl and eflzve remot varie speed can be canes withthe ESCSSOOE Series contotunt. A single emote speed adusiment potentiometer can be used to agustthe engine speed contnuoisy ova specie speed “ange. Select the desired speedrage andthe corespondng ~ potentiometer value. (Refer to TABLE 1H he exact range ‘cannot e four, slet he nest higher ‘ange potentiometer. ‘An adeitnal ed resistor ray be paced across te poten ‘meter to cian te exact desred range. Connect the speed ‘ange poenomster as shown in agra 2 ‘Tomaintan engine stabity tthe minimum speed song, 2 ‘small aroun of droop canbe added using the DROOP ‘adjustment Atthe maximum sped sting he governor perfomance wil be neat soctronaus, gars of he oop ‘agjustment sting, Contact he factory for assistance afcuty is experience in baring tne dose vale speed covering perernance TABLE 1. Variable Speed Range Potetometer Value Speed Range Poeriometer Value 00H, 1K 200 He, 5K 3.000 He, 0K 500K 25K 700K, 50K DIAGRAM2. 6 J k L S = 2 Se S ow “Selec Proper Potentometer Value rom Table 1.‘SYSTEM TROUBLESHOOTING SYSTEMINOPERATVE = Itt engine governing system doesnot function, the faut may be determined by peritring the votage este descr in ‘Slop 1,23, and 4. (+) a |) ofr o meta pola. Should neal values be indeted asa rest of folowing the rouble shooting steps, the faut may be wih the actuator or he wing tothe actuator. See the acter publication or tstng des ‘STEP TERWINALS NORMAL READING ‘PROBABLE CAUSE OF ABNORWAL READING 1 FV)REG) Baer Sippy Votage(120r24VOC) 1. DE bay power at connected, Chek row fe. 2 Low baer tage 3 Wig era. 2 aD 1.OVAC RIS min. wl rang 1.Gap teen set Senso and arth oa eat, Check. : 2 prope doth wing We sees sors Fesstancebameen rms Cand D haul be 30 to 20a 4. Deere peo sneer 3 PEGE 10¥0C, eemal Spo 1, Shertontrinl (Thiwlcause delectve wt) 2 Delecive Speed Coil 4 FARA) 10-20 VDC whiacraming 1 SPEED stent seco bw 2 Shrtepen setae ng, {Detect sped cota. > 4 Detective actuator Soe Actor Treesaang UNSATISFACTORY PERFORMANCE : the governing system functions poo perform the following ts, Swerow TEST ‘PROBABLE FAULT Enghe overspeass | Donoternk Asp OCpowera he 1 Actor goss off. The, decomect peed ‘omer Siem Sereorat Terre C40. act si t f-spoot conta unt eee sutra minim uo pos -eronees sped ‘Son Check span sere. 2.Maraaly hol he ng tt 1.0 vtage edn is 10162000, ‘ested rung speed Measure he 5) SPEED asin et tove desired pee. Dc vrijetaqen Tema A) 2) Delco speed col {FL ontespeodcanez unt 2.1 vagereadeg above 20 VOC, 2) Achat ringers 8 fe votage readings bow 10 VOC, 3)Delecive sped eel nt Gan ettooion ‘ete does rt | |. Measure the votage ate baer “ie vooge isles tan 7 for 9 12 aytm, or rere iy, icra, 14 fora 24V esto replace he bate His weak cruncrs, 2.Morerany const TeminlsAsnd ‘Actor tay wg in er. Frinescustirehoud mow othetal 2 Achalerer kage Bing. ‘ue potion. 5 Osecineacater See actor rebleshacthg, 4 Fse oper. Chest or startin actor or cht wing hares Ergoe romaine 1. Mensur te eto out {1 tatog measurements wit apse 2 vats Delon ese Tomine nnong unc tte tat sip vetogehen be cona govemes spot 2vemar arto, rescea tem reaching fl poskon Posey ue ‘wetetowc romine mera gover, carro sping or inane sare 2 Spo sting 0 owSYSTEM TROUBLESHOOTING Fossbiy of missed or extra pss. The sped col un wit {over wel with 05 vos RMS speed senor signal. A speed Sensar signal of 3 vols RMS or greater at governed speeds recommended. Measurement of te signal's made at Termi- ral and. “The amplitude ofthe speed sensor signal canbe ised by reducing the gap between the speed sensor tp ad ihe engine find gat. The gap should nl be any small than 0.020 n (0.45 mi). When the engine is stopped, back the speed ‘sensor ou by 3 tun afte oucing the ring gear tot to achieve a satisfactory airgep. Electemagnetc Compatity (EMC) EW SUSCEPTIBILITY The goverex system can be ac- versa tla by age tren slat te conduc through the abing othrough direct raat into the conto! create AIGAC speed contol units coin ites and shielding (esgned to protect he untssenstive cuts rom moderate external teeing sources. Athough itis cut to predict ives of interterence, applic. tens fatincude ragheos, sod state ignition systoms, radio transmits, volage reputors or battery chargers shoud be ‘considered suspect as possbe interfering sources. its suspocod that externa fs, ether those that are ‘adel oF conducts. aeor wl fect he govera ystems ‘operation, ts recommended to use shielded cable fo al tetera cornecions. Be sure that onl one end ofthe shies, Incusng the speed senso shel, conecte to singe point on te case of he sped contol unt. Mout the speed ‘oil unto a grounded metal back piste or place tina ‘ead metal bor Raciation's when the interfering signals radiated directly through space he govering sys. To iste he gover- rar sem acronis fom is Woe ef mtence suc, 2 ‘metal shield ra sod metal containers usually elecive. Conduction is when he inertering signals conducted trough the interconnecting wing to the governor system electrics. Shielded cabes and instaling fiers ar common remedies. As anid 1 hel reduce te levels of EM ofa conductive ‘nature, abate ne fit and shielded cates are conve- ent supplied by GAC mn KTIS0. To reduce ne levels of EM ofa raiatod nature a shielded container PIN CATI4 canbe sourced from GAC ands dsb, Insever igh enerayiterfrence oats such as when the governor system rec} inthe eld ofa powedl wansi- {ng sous, he sikng may require tbe a spec EM css shielding For ese condos, contac GAC aplication eng- neering for specific recommendations. Inaba Insabty na closed loop speed conto system can be ‘atogorize nto two general ypes. PERIODIC appeas tobe Srusodal and ata rogar ate NON-PERIODIC is a ardor wandering a af Gecasionaldeviaon rom a steady sate band for no apparent reason, ‘Switch C1 contol the “Lead Cul” ound inthe ESDS500. ‘The natal postions “ON Move the swich to the OFF” ‘poston theres ast nstabily ine sytem, ‘Switch C2 cntls an aditnal rut added nthe 305500 thal designed to einae fst era governr behav, Caused by ver sf or worn couplings inthe die tain between the engine and generator. The nara poston s "OFF" Move oe ON" poston fast erate engine behavior ue toa Sof couping fs experience. ‘The PERIODIC ype can be furor classified as fas or sow instabiry Fast nsttity fa 3 Hor festrirogulrty of he ‘Speed andisusvay ater. Slow period instal is below 3, can be very So, ads soretimes violent fast instabity occurs, tis is typically the governor respond- ingio engine rings. Raising the engine speed meveass the frequency o instability and vce versa. nts cas, pacing ‘sich Cin the “OF positon wil reduce te speed contl nits sensi o righ requency sgnals.Reacus the GAIN ‘and STABILITY fo optimum conto. Should stably stil be ‘resent te removal of to 2 jumper may help sicbize the engine, Post nations are lusated in Diagram 1. gai, Feadusthe GAIN and STABILITY for optimum col. rter- ference rom power electrical signals can also be the cause. ‘Tuff the battery chargers or oer electrical equpmentto soe te system disappears. Slow instbty can have many causes. Adjustment ofthe GGAIN and STABILITY usualy cures most stuators by math. ing the speed convol unit dyeamis. hss unsuccessful, the ‘eadltime compensation canbe modified. Add acapactor from posts £2 to £3 (negative on E2). Post ocations are ited in Diagram 1. Start wih 10 nfs, and increase ud Instabiy is elinatd. The contol system can also be opt- ‘ized fr bes perormance by folowing tis procedure | slow instabity is unflecied by tis procedure, evaluate the {uel system and engine performance. Check the ue jst linkage fr tindng, igh icon, or oor inkage. Be sure to check inkage dung engine operaton. Also look at the engine ‘uel system, hreguartes with carburetor fuel injection systems can change engine power with 8 constant rote ‘ating. This can result sped deviations beyond the conta ofthe governor system. Aacing small amount eroop can ‘help table the syste for roubleshootig. [NON-PERIODIC instability shuld spond o the GAIN con {nol neeasng the gin reduces te instability, then the ‘robiemsprobebly with the engine. Higher gan allows the (governor to respond faster and eaect for sturbance, Look for engine mistings, an erat fuel system, ord changes ‘on the engine generar st votagereqatr. the trot is Sight) erate, but perfomance is fast, move switch Ct the OFF posto, Ths willtendo steady the system, unsuccessful in soving instabty, contac the factory for assslance,