Governors America EDG5500 User manual

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EDG5500
Electronic Digital Governor
© 2015 Copyright All Rights Reserved
EDG5500 Electronic Digital Governor 6.15 PIB 4145 G
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INTRODUCTION
SPECIFICATIONS
INSTALLATION
WIRING
PERFORMANCE
Isochronous Operation ± 0.25%
Speed Range / Governor 400Hz - 10 KHz
(200-5000 RPM w/120 tooth flywheel) cont.
Idle Adjust Full Range
Droop Range 1 - 5% regulation
Speed Trim Programmable 0-100%, (default = 5%)
INPUT / OUTPUT
Supply 12-24 VDC Battery Systems (7.0 to 33 VDC)
Polarity Negative Ground
Power Consumption 70mA max. continuous plus actuator current
Speed Sensor Signal 1.0-120 VRMS
Actuator 8-10 Amps Continuous
Load Share/Synchronizer
Input 0-10 VDC ( 5V nominal, reversed, 100Hz / V )
Reverse Power Protection Ye s
Transient Voltage Protection 60V
ENVIRONMENTAL
Ambient Temperature -40° to 85°C (-40 to 180°F)
Relative Humidity up to 95%
All Surface Finishes Fungus Proof and Corrosion Resistant
CE Rated EN55011, EN50081-2, EN50082-2
PHYSICAL
Dimension See Section 3 “Installation”
Weight 1.8 lbs. (820 grams)
Mounting Any position, Vertical Preferred
RELIABILITY
Vibration 7G, 20-100 Hz
Shock 20G Peak
Testing 100% Functional Testing
COMPLIANCE / STANDARDS
Agency CE and RoHS Requirements
Communications SAE J1939 (Option)
Mount in a cabinet, engine
enclosure, or sealed metal box.
Vertical orientation allows for
the draining of fluids in moist
environments.
Avoid Extreme Heat
Internet Connection
Computer
[mm]
in
Dimensions:
GAC’s EDG5500 digital governor is designed to regulate engine speed on diesel
and gaseous-fueled engines. The EDG system is a suitable replacement 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.
With the use of GAC’s Quikset Display, the EDG5500 requires no computer or
internet connection.
* Keep reading for diagrams and/or additional notes
TERM. DEFINITION GAUGE NOTES
AActuator (+) #16 AWG
Not polarity dependent
BActuator (-) #16 AWG
C Magnetic Pickup (+) #20 AWG
* Twist wires 14 turns per foot
D Mag Pickup Ground #20 AWG
E Battery (-) #16 AWG
F Battery (+) #16 AWG
A 15 amp fuse must be installed in the
positive battery lead to protect against
any overload or short circuit
G Ground Signal #16 AWG * Variable speed/trim input & switches
H Not Used
J Variable Speed Input #20 AWG * 5K ΩResistive Potentiometer
K Droop Select #16 AWG * Active when connected to Term. G
L Idle Select #16 AWG * Active when connected to Term. G
M Aux Input #20 AWG * Load sharing / synchronizing, 5V
nominal (0-10V), reverse ramp
N CAN L #20 AWG
* Twist Wires 14 turns per foot.
P CAN H #20 AWG
RECOMMENDATIONS
1. 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.
With Quikset Display
4X
[151]
5.94 [127]
5.00
[7]
0.27
[144]
5.67
[127]
5.00

2© 2015 Copyright All Rights Reserved
EDG5500 Electronic Digital Governor 6.15 PIB 4145 G
WARNING Loss of Magnetic Pickup Sensing
If the EDG5500 detects no input from the magnetic pickup,
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 display will flash the RPM along with the Warning Indica-
tor. Parameters will be unchangeable.
PIN 3 Magnetic Speed Pickup
• Wires must be twisted and/or shielded for their entire length
(14 turns per foot)
• Gap between speed sensor and gear teeth should not be smaller
than 0.02 in. (.51mm)
• Speed sensor voltage should be at least 1VAC RMS during crank
A DCB E F N P
Actuator
Battery
- +
Magnetic
Speed
Pickup
Fuse 15A Max
Ground to Case
(12V or 24V)
A NDCB E HGF LKJ M PA NDCB E HGF LKJ M P
CAN
( Optional )
Accessory
Input
DROOP
IDLE
Variable Speed /
Trim
120 Ohms
( End of CAN bus)
Ground to
Case
Ground to
Case
5DISPLAY & CONTROLS
One row of parameters is displayed at
a time.
Parameter
Adjust Up
Parameter
Adjust
Down
Increment a Parameter Value:
HOLD and TAP or
Rapidly Increment a Value:
HOLD and HOLD or
Locking the Displpay
HOLD and for 2 seconds
“Over Speed” will blink when the unit is in overspeed.
(Cycle power to restart)
After the EDG has detected loss of magnetic
pickup, the display will flash the RPM along
with the Warning Indicator. Parameters will be
unchangeable.
Displays the units for the parameter (e.g. RPM)
Alpha-Numerical Area
Displays the value of a selected parameter or live
running parameter
Numerical Area
Toggle between the 3 views:
Tap or
Throttle, Delta Speed Graph, & Current
Loss of Magnetic Speed Pickup / Overcurrent
21 3
Tap any
For: SPEED
For: IDLE
For: FUEL LIM
Hold
To change the displayed row of parameters:
To view a parameter value in a selected row:
Hold: Button 1
Hold: Button 2
Hold: Button 3
Column Select Buttons
Parameter Adjust
Over Speed
Quikset Menu

3© 2015 Copyright All Rights Reserved
EDG5500 Electronic Digital Governor 6.15 PIB 4145 G
6 7
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FEATURES PRE-START SETUP & QUIKSET PARAMETERS
ADJUSTING FOR STABILITY
Special Menu
Parameter
Quikset Menu
Parameters
MODE VSPD SPEED V. SPEED
Tr i m
(Default) OFF Application Rated Speed (e.g., 1500 RPM)
Speed Trim Percentage
(e.g., 5% = ±90RPM)
Variable
Speed ON
Minimum speed when
potentiometer is at
lowest resistance
(e.g.,1000 RPM)
Maximum Speed when
potentiometer is at the
highest resistance
(e.g., 2000 RPM)
TRIM or VARIABLE SPEED OPERATION
Trim Function - Performs finer adjustments (e.g. generator frequency)
Variable Speed Function - Operates over a larger RPM range
MODE D SW SPEED
SPEED with Auto Offset ON
Controller will run at SPEED (Quikset
Menu) with an offset determined by the
DROOP%
Droop Speed OFF
Controller will run to DSPD (Special
Menu). A manual offset is required for
operation
SPEED DROOP OPERATION
Droop will replicate a mechanical governor’s response to a load change. In
Droop Operation, the engine speed will decrease as engine load increases.
DROOP% (Quikset Menu) is based on the change in current in the actuator
(DRNG see Section 6 Special Menu Parameters) from no load to full load.
IDLE SPEED
ACCESSORY INPUT
The Aux terminal accepts signals from auto synchronizers, load sharing units,
and other GAC accessories.
GAIN - RATED SPEED & IDLE SPEED
Set the parameters below before starting the engine:
#TEETH Input the Number of Teeth on the Flywheel
CRANK Input the Crank Termination (RPM)
SPEED Input the Fixed Speed of the Engine (RPM)
Once the engine is running at operating speed and at no load, the following
governor performance adjustments can be made to increase engine stability. QUIKSET MENU
PARAMETER ADJUSTMENT PROCEDURE
A. GAIN
1.
2.
3.
4.
Increase this parameter until instability develops.
Then, gradually decrease this parameter until stability returns.
Finally, decrease this parameter one increment further to en-
sure stable performance.
If instability persists, adjust the next parameter.
B. STABILITY
1.
2.
Follow the same adjustment procedure as the GAIN
parameter.
If instability persists, adjust the next parameter.
C. DEADTIME 1. Follow the same adjustment procedure as the GAIN
parameter.
ADJUSTABLE QUIKSET PARAMETERS
OVER SPEED #TEETH CRANK
Range: 500 - 9999 RPM
Default: 2220 RPM
Range: 50 - 255
Default: 120
Range: 0 - 9999 RPM
Default: 400 RPM
RPM to automatically
shutoff the actuator
Number of teeth on
flywheel
RPM which EDG switches
to starting fuel ramp
SPEED RAMP V.SPEED LOCKED
Range: 0 - 9999
Default: 400
Range: 0 - 9999 RPM
Default: 5 RPM
Range: OFF, ON
Default: OFF
Rate at which speed
changes from idle to speed
and back
Maximum speed change
allowed from trim input
Indicates if EDG will lock
after 5 minutes of non-use
START FUEL DROOP% FUEL RAMP
Range: 0 - 100%
Default: 99%
Range: 0 - 25.0%
Default: 0.0%
Range: 0 - 100%
Default: 2%
Percent of fuel to apply to
actuator first upon cranking
Droop to apply under
maximum load (based on
current of actuator)
Percent per second to
apply fuel as engine starts
to idle
SPEED IDLE FUEL LIM
Range: 0 - 9999 RPM
Default: 1500 RPM
Range: 0 - 9999 RPM
Default: 900 RPM
Range: 0 - 100%
Default: 99%
Operating speed of engine Speed of engine when
IDLE input is closed
Maximum actuator
percentage allowed
GAIN STABILITY DEADTIME
Range: 0 - 100,
100 = Max Gain
Default: 20
Range: 0 - 100,
100 = fastest response
Default: 36
Range: 0 - 100
Default: 21
Proportional (P) set point
of the PID control at oper-
ating SPEED and IDLE
Integral (I) set point of the
PID control
Derivative (D) set point of
the PID control
GAIN TYPE ADJUSTMENT PROCEDURE
RATED SPEED 1. Selected by default. (Value will remain when switching be-
tween Idle and Rated Gain.
IDLE SPEED
1.
2.
3.
Connect the idle input to ground.
Change GAIN value.
Disconnect Idle input from ground to switch back to Rated.
The optional external switch must be tied to terminal “G”.
Pressure switch may also be used as a method of enabling.
Before adjusting DROOP%, the optional external selector
switch must be in DROOP postition.
IMPORTANT
IMPORTANT
The EDG5500 is equipped with two separate gains, one for rated
speed, the other for idle speed. Both are set using the GAIN setting
on the Quikset menu.
NOTE
Normally, adjustments made at no load achieve satisfactory per-
formance. If further performance improvements are required, refer
to Section (9) ADVANCED PARAMETERS MENU and Section (10) SYSTEM
NOTE

4© 2015 Copyright All Rights Reserved
EDG5500 Electronic Digital Governor 6.15 PIB 4145 G
9 10
SPECIAL PARAMETERS MENU ADVANCED PARAMETERS MENU
SPECIAL MENU PARAMETERS
Parameter Definition Range Default
AUX Auxiliary Input Enable Off, On Off
AVE
On = Averages four pulse samples
from the Mag-Pickup for more
accurate response
Off = Calculates speed from pulses
accumulated over the last sys-
tem update
Off, On Off
VSPD Variable Speed or Trim Select
(On=Variable Speed, Off=Trim) Off, On Off
SOFT Soft Coupling - Dampening of system
(slow down response) Off, On Off
LEAD Lead Circuit - Response increase Off, On Off
D SW
Sets the droop mode
On=Auto Offset
Off = Manual Offset
Off, On On
DITH Adds white noise to actuator or throttle
body prevent sticking in the fuel rack.(%) 0 - 10 0
DRNG System current to the actuator that
represents full load. Units in (A) 0.0 - 10.0 3.9
DSPD Droop offset when DSW is set to Off
(RPM) 0 - 9999 1500
OVRC
Over Current - Turns off actuator if
specified current value is exceeded.
Units in (A)
0 - 12 11.7
Previous
Parameter
Next
Parameter
Selecting Parameters:
Display Special
Menu Parameters:
Hold ALL 3 until
“AUX” appears in display
Return to Quikset Menu: Hold ALL 3 for 2 seconds
Adjust Parameters: Increase
Parameter
Decrease
Parameter
ADVANCED MENU PARAMETERS
Parameter Definition Range Default
RATE The time (mS) between calls to the PID control
loop. 4 - 250 mS 4
FLTR
Number of speed samples in frequency cal-
culation. Filter is active when soft coupling
(SOFT) is set to ON. Lower numbers filter high
frequency noise.
1 - 62
samples 40
GMUL
If the GAIN parameter is at maximum and
more GAIN is required, increase GMUL. GAIN
will be more responsive. If small changes in
the GAIN parameter are over responsive, de-
crease GMUL.
1 - 20 17
SMUL
If the STABILITY parameter is at maximum
and more STABILITY is required, increase
SMUL. STABILITY will be more responsive.
If small changes in STABILITY parameter are
over responsive, decrease SMUL.
1 - 20 17
DMUL
If DEADTIME value is at maximum and more
DEADTIME is required, increase DMUL.
DEADTIME will be more responsive. If small
changes in DEADTIME parameter are over re-
sponsive, decrease DMUL.
1 - 20 12
Advanced Menu Parameters will further adjust engine stability.
DISPLAYING ADVANCED
MENU PARAMETERS:
Hold ALL 3 until
“RATE” appears in display.
Return to Quikset Menu: Hold ALL 3 for 2 seconds
Adjust Parameters: Increase
Parameter
Decrease
Parameter
11 SYSTEM TROUBLESHOOTING
If the engine governing system does not function, the fault may be determined by performing the voltage tests described in Steps 1 through 3. 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.
SYSTEM INOPERATIVE
STEP WIRES NORMAL READING PROBABLE CAUSE OF
ABNORMAL READING
1 F(+) & E(-)
Battery Supply
Voltage
(12 or 24V DC)
1.
2.
3.
DC battery power not connected. Check for blown fuse
Low battery voltage
Wiring error
2 C & D 1.0V AC RMS min.
While Cranking
1.
2.
3.
Gap between speed sensor and gear teeth too great
Improper or defective wiring to the speed sensor
Resistance between D and C should be 130 to 1200 ohms. See specific mag pickup data for resistance.
Defective speed sensor.
3 F(+) & A(-)
1.0 - 2.0V DC
While Cranking
1.
2.
3.
4.
5.
SPEED or IDLE parameter set imcorrectly
CRANK or START FUEL set incorrectly
Short/open in actuator wiring
Defective speed control
Defective actuator, see Actuator Troubleshooting
To change parameters, refer to Section 4 DISPLAY & CONTROLS.
NOTE
Multiplier Changes can make drastic changes. Changing a multi-
plier (e.g. GMUL) will affect the corresponding Quikset parame-
ter (e.g. GAIN) in two ways:
1. If the multiplier is decreased by 1, corresponding Quikset
value will double.
2. If the multiplier is increased by 1, corresponding Quikset
value will halve.
CAUTION
The engine will maintain current operation while adjusting param-
eters. ( i.e. NO CHANGES ) Since the scaling will be made to the
Gain, Stability, and Derivitive parameters automatically, go back and readjust
these parameters to the diesired levels.
NOTE

5© 2015 Copyright All Rights Reserved
EDG5500 Electronic Digital Governor 6.15 PIB 4145 G
INSTABILITY
INSTABILITY SYMPTOM PROBABLE CAUSE OF
ABNORMAL READING
Fast Periodic
The engine seems to jitter with
a 3Hz or faster irregularity of
speed. (Not as moderate)
1.
2.
3.
Make sure LEAD Special parameter is set to “OFF”.
Readjust the GAIN and STABILITY for optimum control.
In extreme cases, decrease the DEADTIME parameter.
Slow Periodic Speed irregularity below 3Hz.
(Sometimes severe)
1.
2.
3.
4.
Verify the SOFT (soft coupling) Special Manu parameter is disabled.
Decrease the update rate of the controller by decreasing the RATE Advanced parameter.
(Each time RATE is changed, GAIN, STABILITY, and DEADTIME must be re-adjusted.
Check fuel system linkage during engine operation for:
a. binding
b. high friction
c. poor linkage
Dead Time Parameter set too high.
Non-Periodic Erratic Engine Behavior
1. Increasing the GAIN should reduce the instability but not totaly 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 genera
tor set voltage regulator.
If unsuccessful in solving instability, contact GAC for assistance.
[e-mail] or call: 413-233-1888
UNSATISFACTORY PERFORMANCE
SYMPTOM NORMAL
READING
PROBABLE CAUSE OF
ABNORMAL READING
Engine Over Speeds
1. Do Not Crank. Apply DC power to the governor
system.
1. If the actuator is at minimum fuel position and there exists an erroneous
position signal, then check speed sensor.
2. Manually hold the engine at the desired running
speed. Measure the DC voltage between Termi-
nals A(-) & F(+) on the speed control unit.
1.
2.
3.
If the voltage reading is
1.0 to 2.0V DC:
a. SPEED parameter set above desired speed
b. Defective speed control unit
If voltage reading is > 2.0V DC then check for:
a. actuator binding
b. linkage binding
If the voltage reading is below 1.0V DC:
a. Defective speed control unit
3. Check #TEETH parameter. 1. Incorrect tooth count entered.
Over Speed shuts down
engine after running
speed is reached
1. Examine the SPEED and OVER SPEED oper-
ating parameters for the engine
1.
2.
3.
4.
5.
6.
SPEED parameter set too high.
OVER SPEED set too close to SPEED.
Check SPEED RAMP parameter.
Actuator or linkage binding.
Speed Control unit defective.
Gain too low.
Over Speed shuts down
engine before running
speed is reached
1. Check resistance between Terminals C&D.
Should be 130 to 1200 ohms. See specific
Magnetic Pick-up data for resistance.
1.
2.
OVER SPEED set too low
If the speed sensor signal is erroneous, then check the wiring.
Actuator does not
energize fully
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: 1. Check wiring
2. Check circuit protection/relay
3. Check charging system
4. Check battery
2. Momentarily connect Terminals B and F. The
actuator should move to the full fuel position.
1.
2.
3.
4.
5.
Actuator or battery wiring in error
Actuator or linkage binding
Defective actuator
Fuse open. Check for short in
actuator or harness.
Check START FUEL and CRANK
Engine remains below
desired governed speed
1. Measure the actuator output, Terminals A & B,
while running under governor control.
1.
2.
If voltage measurement is within 2V DC of the battery supply voltage
level, then fuel control is restricted from reaching full fuel position, pos-
sibly due to mechanical governor, carburetor spring, or linkage inter-
ference.
Check SPEED, IDLE, GAIN, START FUEL, and CRANK
720 Silver Street,
Agawam, MA 01001 USA
[e-mail]
www.governors-america.com