Governors America ESD2200 Series User manual

1Governors America Corp. © 2020 Copyright All Rights Reserved
ESD2200 Speed Controller 6-2020-A2 PIB1022
1
ESD2200 Series
Speed Control Unit
2SPECIFICATIONS
PERFORMANCE
Isochronous Operation ± 0.25 % or better
Speed Range / Governor 1 - 7.5 KHz Continuous
Speed Drift with
Temperature ±1% MAX
Speed Trim Range ± 250 Hz
Terminal A Sensitivity 130 Hz. ±15 Hz / V
@ 5.1 K Impedance
INPUT / OUTPUT
DC Supply 12-24 VDC ±30% Battery Systems
Transient and Reverse
Voltage Protected*
Polarity Negative Ground (Case Isolated)
Power Consumption 60 mA continuous
plus actuator current
Actuator Current
@ 77 °F (25 °C) 10 A MAX Continuous
Speed Sensor Signal 1.0 - 50 V RMS
RELIABILITY
Vibration 5 g @ 20-500 Hz
Testing Functionally Tested
ENVIRONMENTAL
Ambient Temperature -40° to 85 °C (-40 to 185 °F)
Relative Humidity up to 100 %
All Surface Finishes Fungus-Proof
and Corrosion-Resistant
PHYSICAL
Dimension See Section 3, Installation
Weight 12 ozf (347 gf)
Mounting Any Position, Vertical Preferred
* Reverse voltage is protected against by a parallel diode. A 15 A fuse must
be installed in the positive battery lead. See Section 4, Wiring.
COMPLIANCE / STANDARDS
Agency: CE, (EMC: EN55011, EN55014, EN55022, EN60034
& EN61000)
1OVERVIEW
PART NUMBER FEATURE / PRODUCT DETAILS 12V 24V
ESD2210 Standard Unit
ESD2241 Standard Unit with Idle
ESD2244 Light Force (Low-Current Optimized PID)
The ESD2200 Series speed control unit is an all- electronic device
designed to control engine speed with fast and precise response
to transient load changes.
This closed loop control, when connected to a proportional electric
actuator and supplied with a magnetic speed sensor signal, will
control a wide variety of engines in an isochronous or droop mode.
It is designed for high reliability and it's hard potted to withstand
the engine environment.
◊ 12 or 24VDC
◊ Isochronous Operation
◊ Precise Speed Control
◊ Adjustable PID Functions
◊ 8:1 Speed Range Control
◊ Light Force Option Available

2Governors America Corp. © 2020 Copyright All Rights Reserved
ESD2200 Speed Controller 6-2020-A2 PIB1022
3INSTALLATION
Dimensions:
in
(mm)
Mount in a cabinet, engine en-
closure, or sealed metal box.
Vertical orientation allows for
thedrainingofuidsinmoist
environments.
Avoid Extreme Heat
Use an overspeed shutdown device, independent of the governor system, to prevent loss of engine control
which may cause personal injury or equipment damage.
Donotrelyexclusivelyonthegovernorsystemelectricactuatortopreventoverspeed.Asecondaryshuto󰀨
device, such as a fuel solenoid must be used.

3Governors America Corp. © 2020 Copyright All Rights Reserved
ESD2200 Speed Controller 6-2020-A2 PIB1022
3
4WIRING
TERMINAL DEFINITION NOTES
A & B Speed Trim 18 AWG (1.3mm sq) or larger wire
C & D
Magnetic Speed
Pickup
(D is ground)
Wires must be twisted and/or shielded for their entire length
Gap between speed sensor and gear teeth should not be smaller than 0.02 in. (.51mm)
Speed sensor voltage should be at least 1V AC RMS during crank
E & F Battery Power
(+/-)
16 AWG (1.3mm sw) or larger wire
A 15 A fuse must be installed in the positive battery lead to protect against reverse voltage
Battery positive (+) input is Terminal E
G & H Actuator (+/-) 16 AWG (1.3mm sw) or larger wire
RECOMMENDATIONS
1.
2.
Shielded cable should be used for all external connections to the ESD control.
One end of each shield, including the speed sensor shield, should be grounded to a single point on the ESD case.
ESD2210 and ESD2244 WIRING DIAGRAM

4Governors America Corp. © 2020 Copyright All Rights Reserved
ESD2200 Speed Controller 6-2020-A2 PIB1022
ESD2241 WIRING DIAGRAM
4WIRING (CONTINUED)
TERMINAL DEFINITION NOTES
A & B Idle Switch Open for Idle, Closed for Run Speed
C & D Magnetic Speed Pickup
(D is ground)
Wires must be twisted and/or shielded for their entire length
Gap between speed sensor and gear teeth should not be smaller than 0.02 in. (.51mm)
Speed sensor voltage should be at least 1V AC RMS during crank
E & F Battery Power (+/-)
#16 AWG (1.3mm sw) or larger wire
A 15 amp fuse must be installed in the
positive battery lead to protect against reverse voltage
Battery positive (+) input is Terminal E
G & H Actuator (+/-) #16 AWG (1.3mm sw) or larger wire
RECOMMENDATIONS
1.
2.
Shielded cable should be used for all external connections to the ESD control.
One end of each shield, including the speed sensor shield, should be grounded to a single point on the ESD case.

5Governors America Corp. © 2020 Copyright All Rights Reserved
ESD2200 Speed Controller 6-2020-A2 PIB1022
5
6
STARTING ThE ENGINE
ADJUSTING FOR STABILITY
The speed control unit governed speed setting is factory set at approximately engine idle speed (1000 Hz., Speed sensor signal or 600
RPM).
Crank the engine with DC power applied to the governor system. The actuator will energize to the maximum fuel position until the en-
gine starts. The governor system should control the engine at a low idle speed. If the engine is unstable after starting, see Section 6,
Adjusting for Stability.
START FUEL ADJUSTMENT
1. Rotate the GAIN adjustment clockwise until instability develops.
2. Gradually move the adjustment counterclockwise until stability returns.
3. Move the adjustment one division further counterclockwise to ensure
stable performance (270° pot).
4. Rotate the STABILITY adjustment clockwise until instability develops.
5. Gradually move the adjustment counterclockwise until stability returns.
6. Move the adjustment one division further to insure stable performance
(270° pot).
7. Gain and stability adjustments may require minor changes after en-
gine load is applied. Normally, adjustments made at no load achieve
satisfactory performance.
Gain Middle Position
Stability Middle Position
Speed Trim Control (Infused) Middle Position
IMPORTANT Make the following adjustments before starting the engine.
The governed speed set point is increased by clockwise rotation of the SPEED adjustment control. Remote speed
adjustment can be obtained with an optional 5K Speed Trim Control.
NOTE
Once the engine is running at operating speed and at no load, the following governor performance adjustments can be made to in-
crease engine stability.
If instability persists or further performance improvements are required, see Section 7, System Troubleshooting.
NOTE
SPEED GAIN
STABILITY
E4
E5
25x
ESD2210 and ESD2221 ESD2241

6Governors America Corp. © 2020 Copyright All Rights Reserved
ESD2200 Speed Controller 6-2020-A2 PIB1022
6
SYMPTOM NORMAL READING PROBABLE CAUSE
Engine
Overspeeds
1. Do Not Crank. Apply DC power to the
governor system.
1.
2.
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.
If the actuator is at minimum fuel position and there exists an
erroneous position signal, then check speed sensor cable.
2. Manually hold the engine at the desired
running speed. Measure the DC voltage
between Terminals H(-) & E(+) on the
speed control unit.
1.
2.
3.
4.
If the voltage reading is
1.0 to 1.5 V DC:
a. SPEED adjustment is set
above desired speed
b. Defective speed control unit
If voltage reading is above 1.5 V DC then check for:
a. actuator binding
b. linkage binding
Set point of overspeed shutdown set too low.
If the voltage reading is below 0.8 V DC:
a. Defective speed control unit
Actuator does not
energize fully
1. Measure voltage between Terminals H(-)
& E(+) on the speed control unit. Should
be 0.8 to 1.5 V.
1.
2.
3.
Replace the battery if weak or undersized.
Actuator wiring incorrect.
If the voltage is less than 1.5 V DC: SPEED set too low.
2. Momentarily connect Terminals E to H.
The actuator should move to the full fuel
position.
1.
2.
3.
Actuator or battery wiring in error
Actuator or linkage binding
Defective actuator
Engine remains
below desired
governed speed
1. Measure the actuator output, Terminals G
& H, while running under governor control.
1.
2.
If voltage measurement is within 1.5 V DC 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.
If not, increase speed setting.
7SYSTEM 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o󰀨,exceptwherenoted.
See actuator publication for testing procedure on the actuator.
STEP WIRES NORMAL READING PROBABLE CAUSE
1 E(+) & F(-)
Battery Supply
Voltage
(12, 24, or 32 V DC)
1.
2.
3.
DC battery power not connected. Check for blown fuse.
Low battery voltage
Wiring error
2 A(+) & B(-) 0-3.9 with speed trim. 7.1-
7.9 without speed trim.
1.
2.
Speed trim shorted or miswired.
Defective unit.
3 C(+) & D(-) 1.0 V AC minimum while
cranking
1.
2.
3.
Gap between speed sensor and gear teeth too great.
Improper or defective wiring to the speed sensor. Resistance should be between 30 to
1200Ω.
Defective speed sensor.
4 H(-) & E(+) 0.8-1.5 V while cranking
1.
2.
3.
Wiring error to actuator.
Defective speed control unit.
Defective actuator.
57(+) & 10(-)
while cranking 8.4-9.4 V
1.
2.
3.
4.
SPEED adjustment set too low.
Wiring error to actuator.
Defective speed control unit.
Defective actuator.
6 6(+) & 2(-) 0.2-1.0 V while cranking
1.
2.
3.
Wiring error to actuator
Defective speed control unit
Defective actuator
SYSTEM INOPERATIVE
UNSATISFACTORY PERFORMANCE

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ESD2200 Speed Controller 6-2020-A2 PIB1022
7
INSTABILITY SYMPTOM PROBABLE CAUSE
Fast Periodic The engine seems to jit-
ter with a 3 Hz or faster
irregularity of speed.
1.
2.
3.
Remove the E1 to E2 jumper. Readjust GAIN and Stability afterward.
Jumper between E4 and E5 may be removed to further stabilize the system.
Turno󰀨otherelectricalequipmentthatmaybecausinginterference.
Slow Periodic An irregularity of speed
below 3 Hz.
1.
2.
3.
Readjust the GAIN and STABILITY
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.
Check fuel system linkage during engine operation for:
a. binding
b. high friction
c. poor linkage
Non-Periodic Erratic Engine Behavior 1.
2.
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-rings
b. an erratic fuel system
c. load changes on the generator set voltage regulator.
If throttle is slightly erratic, but performance is fast, then removing the jumper from E4 to E5 will
tend to steady the system.
A strong magnetic speed sensor signal will eliminate the possibility of missed or extra pulses. The speed control unit will govern well with
0.5 V RMS speed sensor signal. A speed sensor signal of 3 V AC 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.
7SYSTEM TROUBLEShOOTING (CONTINUED)
INSTABILITY
INSUFFICIENT MAGNETIC SPEED SIGNAL