‘overnons ESD5500E Series MERICA Speed Control Unit one: Geena Orme Ee ae ‘The ESD5S00E Series Speed Control Unit is an al-olectronic device designed to control ‘engine speed quickly and precisely in response to transient load changes. The ESDSSOOE controls @ wide variety of engines in isochronous or droop mode when ‘connected to a proportional electric actuator and magnetic speed sensor. The ruggedly built ESDSSO0E series is designed to withstand the engine environment. Light-Force variations are avaliable. MODEL DESCRIPTION ESDSSO0E Mul: VDC/ Standard Unit ESD5520E _Muli-VDC / Light-Force (Low-Current Optimized PID) / Enhanced Droop Mult-VDC / Light-Force (Low-Current Optimized PID) | Enhanced Droop ESOSS22E for Cummins EFC Forward Acting (Normaly Closed) Mul-VDC / Light-Force (Low-Current Optimized PID) / Ant-Windup ESDS526E Circuit (Gaseous) / Recommended for T1/T2 ATES Espsszee Mult-VDC /Anti-Windup Circuit (Gaseous) / Recommended for T3/T4 me SPECIFICATIONS SI RELABILTY Idle Adjust Clockwise 60% of Set Speed ENVIRONMENTS Idle Adjust Counterclockwise Less than 1200 Hz ‘Ambient Temperature ~A0" to 85°C (-40" to 180°F) plese Droop Adjust Minimum. 15 Hz £75 Hz per 1.0 A change Com EUS Anoans) pt ae Seenineors Sete = Been coer — ER , took stot @ £080 meen L 735 Hz #60 Hz/Volt @ 65.0 kO Impedance Weight 1-20 Ib (0.54 kat) u 448 He 210 Havok @) 1 MO impedence ‘Mounting Any position, vertical preferred wweuroureur — Vette Ged Ce oe) paeommeen Simtantnnu pus curt ers Een Maximum 10.0 + Protected against shor cei io actuate shuts of curento actus) unt automaticaly tums on whan shore removed “~ Protected again revrsevallage bya saree dodo, A5 amp fuse must be insted he postive batery ad ESDSSO0E Series Speed Conto! Unit 3-2020-€1 [PIB 1002: ‘Governors America Corp. © 2020 Copyright All Rights ReservedINSEE een neo 5.750, Vertical orientation (46) a eatin (26) ments. © 5.000 ti27] ole °0O Avoid Extreme Heat Mount ina cabinet, engine enclosure, or Sealed metal box @O®@® Dinersns (ren) 0.266 (68) BATTER a ESOSSO0E Series Speed Control Unit 3-2020-€1 [PIBT002: ‘Governors America Corp. © 2020 Copyright All Rights Reserved(ONTINUED) CIN When wiring ESDSSOOE Series controllers: Use shielded cable forall extemal connections to the ESD controller. (One end of each shield, including the speed sensor shield, should be grounded to a single point on the ESD case. ‘Terminal A, B, E,and F should be 16 AWG or larger. Long cables require increased wie size to minimize voltage drops. Battery positive (+) Terminal F should be fused for 15 A, ‘Magnetle speed sensors Terminals C and D must be twisted and or shielded for the entire length, ‘The gap between the speed sensor and the ring gear teeth should be smaller than 0,02 in [0.5 mm] usually backing out 3/4 turn after touching ring gear teeth, Speed sensor voltage should be at lease 1V AC RMS during cranking. If auto synchronization is used alone, not with a load sharing module, use a 3 0 resistor between Terminal N and P to match the voltage between the speed control unit and the synchronizer. 8. When operating at the upper end of the control unit frequency range, add a jumper wire between Terminal G and J to increase the fre- quency range of the control unit over 7000 Hz 8. Terminal P is used to supply +10 V DC regulated supply to accessories. No more than 20 mA of current can be drawn from this supply. Ground reference is Terminal G. A short circuit inthis terminal can damage the speed control unit ‘An overspeed shutdown device, independent of the governor system, must be provided to prevent loss of fengine control which may cause personal injury or equipment damage. Do not rely exclusively on the governor system to prevent overspeed. A secondary shutoff device such as a fuel solenoid must be used TERMINAL DEFINITION Notes A&B Actuator (+) 18 AWG (1.3mm) or larger wire Wires must be twisted andor shielded for their entire length ‘Gap between speed sensor and gear teth should not be smaller than 0.02 in. 'Stmm) + Spoed sensor voltage needs tobe al last 1 V RMS during crank Magnetic Speed Pickup C80 (Pie ground) + 18AWG (1.3mm or larger wie E&F ——Batiory Power (J+) + ATSAtuse must be insallod inthe Postive battery lea to protect agains reverse voltage + Battery postive (+) Input i Terminal F cs {Ground Signal 4 For 12.V systems with actuator currents above 5A, may sometimes requir a jumper between Terminals Hand G Variable Speed 5 kA. resistive nominal K&L Droop Select ‘Activa when closed ™ Idle Select Close fr lle N Accessory Input Load SharingSynctronizing, 0-10 V DC (SV Nominal, Reversed, 148 Hz1V). Shielded cabling recommended. P ‘Accessory Power Supply 10\VDC Output To Power GAC Load Sharing and Synchronizing Modules ADDING A POTENTIOMETER Use a single remote speed adjustment potentiometer to adjust engine speed. Select the desired speed range and the corresponding potent fometer value. Ifthe exact range is not found select the next higher range potentiometer. Connect the potentiometer as shown in the potentiometer diagram, ESDSSO0E Series Speed Conto! Unit 3-2020-€1 [PIB 1002: ‘Governors America Corp. © 2020 Copyright All Rights ReservedON Make sure the following adjustments are set before starting the engine. GAIN Mile Postion STABILITY Mile Postion ‘SPEED TRIM CONTROL Mise Postion STARTING FUEL Full OW (MAK fue) SPEED RAMPING Full COW (estest) | 6 | start THE ENGINE ‘The speed control unit govemed speed selting is factory set at approximately engine idle speed. (1000 Hz., speed sensor signal or 600 RPM) If the engine does not start, adjustment of the speed potentiometer may be required. Crank the engine with DC power applied to the governor system. The actuator will energize to the maximum fuel position until the engine starls. The governor system should control the engine at a low idle speed. Ifthe engine is unstable after starting, refer to Section 8 ADJUST- ING FOR STABILITY. GOVERNOR SPEED SETTING IMPORTANT: sree Al Speed Adjustment Is a 25 Tur Potentiometer | 8. | ADJUSTING FOR STABILITY (Once the engine is running at operating speed and at no load, the following governor performance adjustments can be made to increase STABILITY engine stability. c Normal, adjustments made at no load achieve satistac- tory perfomance. further performance improvements ad are required, eer to Secton 12 TROUBLESHOOTING DEAD TIME ‘COMPENSATION SUPER PARAMETER PROCEDURE GAIN 4. Rotate the GAIN adjustment clockwise until instability develops. 2. Gradually move the adjustment counterclockwise (CCW) untl stability returns. 3. Move the adjustment one division further counterclockwise to ensure stable performance (270° potentiometer) 4. Ifinstabilty persists, adjust the next parameter. STABILITY Follow the same adjustment procedure, steps 1 -3, as the GAIN parameter ESOSSO0E Series Speed Control Unit 3-2020-€1 [PIBT002: ‘Governors America Corp. © 2020 Copyright All Rights Reserved| 9 | startING FUEL ADJUSTMENT ‘The engine’s exhaust smoke at star-up can be minimized by complet ing the folowing adjustments: 1. Place the engine in idle by connecting Terminals M and G. 2. Adjust the IDLE speed for as low a speed setting as the appi- cation allows. Idle speed must be set for proper start fuel and speed ramping function, even if the idle feature is not used. 3, Adjust the STARTING FUEL CCW until the engine speed begins to fall Inorease the STARTING FUEL slightly so that the idle speed is retumed to the desired level 4. Stop the engine. SN Cn of we meheds of opeaon fhe ESDSSIOE maybe elected Operating Speed oe METHOD 1 - OPERATING SPEED METHOD 2- IDLE SPEED Start the engine and accelerate direcly to the operating speed (Gen- Start the engine and maintain at an idle speed for a period of time ‘erator Sets, etc) prior to accelerating to the operating speed. This method separates PROCEDURE the starting process so that each may be optimized for the lowest smoke emissions, 1. Remove the connection between Terminals M and G. 2. Start the engine and adjust the SPEED RAMPING for the least PROCEDURE ‘smoke on acceleration rom ide to rated speed, 41, Replace the connection between Terminals M & G with atog- 3. Ifthe starting time is too long, the STARTING FUEL may needto _—_gle switch or a normally open water jacket temperature switch. be adjusted slightly clockwise (CW), Giher optical switch combinations can be used 2, Start the engine 3, Ifthe starting smoke is excessive, the STARTING FUEL may need to be adjusted slightly CCW. 4, Ifthe starting time is too long, the STARTING FUEL may need tobe adjusted slightly Cw. Full CW Full CCW: 5, When the switch opens, adjust the SPEED RAMPING for the least amount of smoke when accelerating from idle speed to rated speed. SPEED RAMPING ESOSSO0E Series Speed Control Unit 3-2020-€1 [PIBT002: ‘Governors America Corp. © 2020 Copyright All Rights ReservedHI oN IDLE SPEED SETTING Ifthe IDLE speed setting was not adjusted as detailed in Section 9 Starting Fuel Adjustment, then place the optional external selector switch in the IDLE position, The idle speed set point is increased by the clockwise rotation of the IDLE adjustment control. When the engine is at idle speed, the speed control unit SPEED plies droop to the governor system to ensure stable operation. tf not using the idle method, you can lower idle tothe bare minimum (even fits ‘not being used) for smoke reduction LEAD CIRCUIT & SOFT COUPLING ‘Switch 1(C1) controls the Lead Circuit, The normal position is ON. Move the switch to the OFF position if there is fast instabilly in the system. ‘Switch 2(C2) controls a circuit designed to eliminate fast erratic gover= nor behavior, caused by very soft or wom couplings in the drive train between the engine and generator. ‘The normal position is OFF. Use the ON position if you experience fast erratic engine behavior between the engine and generator due to a soft coupling. ACCESSORY INPUT The Auxiliary Terminal N accepts input signals from load sharing units, auto synchronizers, and other governor system accessories, GAC ac- ie cessories are direcily connected to this terminal When an accessory is connected to Terminal N, the speed will de- i crease and the speed adjustment must be reset. i Ifthe auto synchronizer is used alone, notin conjunction witha load shar- ing module, a3 0 resistor should be connected between Terminals N and P. This is required to match the voltage levels between the speed control : Unit and the synchronizer, einen ACCESSORY SUPPLY ‘The +10 volt regulated supply, Terminal P, can be utlized to provide power to GAC governor system accessories. Up to 20 mAof current can bbe drawn from this supply. Ground reference is Terminal G, ‘Asshort circuit on this terminal can damage the speed control unit, Do not connect Terminals N and P directly to each other. ESDSSO0E Series Speed Conto! Unit 3-2020-€1 [PIB 1002: ‘Governors America Corp. © 2020 Copyright All Rights ReservedDDITIC L FEATURES & OPTIONAL WIRIN eo) REMOTE VARIABLE SPEED OPERATION AA 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 (See Variable Speed Table) . f the exact range cannot be found, select the next higher range potentiometer. ‘To maintain engine stablity at the minimum speed setting, a small amount of droop can be added using the DROOP adjustment. At the max- imum speed setting the governor performance will be near Isochronous, regardless of the droop adjustment setting, ‘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 dficlly is experienced in obtaining the desired variable speed governing performance. VARIABLE SPEED TABLE Potenometer wing ‘SPEED FREQUENCY RANGE POTENTIOMETER VALUE, 900 Hz 1ko 2400 He 5ka GHJ 3000 Hz 10K = 3500 Hz 25k0 S 3700 He 50kO ‘Sete Proper Ptentometer Conversion Formulas = (RPM x #Teeth) (Hetty cae X80) He = BPM ATE) apyy = MEwenoan X60) namo a a ro ‘The ESD5500 series of controllers have the abil to expand the speed range by placing a jumper wire across terminals, Gand J, The standard range is 7400 Hz however this is based on the operating speed and the number of flywheel teeth (see formula). If your application is above this frequency, or near it~ place the jumper and test again. Ths is an important step if your engine is not able to reach rated speed but the actuator isnot saturated ‘SPEED DROOP OPERATION 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 ful oad. Place the optional external selector switch in the OROOP 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. prgrgg Though awid range of doops avalabe wih the intel contol, droop level requirements of 10% are unusual. oop ibvels experienced ar higher rower ian tage fequred, contact GRC or asstance. ESDSSO0E Series Speed Conto! Unit 3-2020-€1 [PIB 1002: ‘Governors America Corp. © 2020 Copyright All Rights ReservedTROUBLESHOOTING Ifthe 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 your actuator publication for actuator testing procedures. SYSTEM INOPERATIVE STEP WIRES CHECK PROBABLE CAUSE 1. DC battery power not connected. Check for blown fuse Battery Supply 1 FW)RER ‘votage 2. Low battery votage (120r24V 00) Wiring enor 1. Gap betwaen speed sensor and gear teat too great. Check Gap. 2 ciH&0,) HOVACRMS min. while 2. Improper or defective wing othe speed sensor Resistance between D and shouldbe 160 to » cranking 1200 0. See your specie mag pickup data for resistance. 3, Defective speed sensor 4. Short on Terminal P 3° PHAGE) 1006, Internal Supply Detective speed control unt 1, SPEED potentiometer st 100 ow 110-20V0Cwnie 2 ShorVopen in actuator wiring 4 Feary ‘cranking a Detective speed control 4. Defective actuator, soe your actuator manual for toubleshooting INSUFFICIENT MAGNETIC SPEED SIGNAL ‘A strong magnetic speed sensor signal eliminates the possibilty of missed or extra pulses. The speed control unit will govern well with 1.0 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 0.02 in [0.5 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, INSTABILITY INSTABILITY CHECK PROBABLE CAUSE 1. Make sure switch C1 is sotto OFF ‘The engine seems ojter 2. Readjust the GAIN and STABILITY fr optimum contol FastPeriodie with a 3Hz of faster rragu- Tanty of speed 3. Remove the E1 to E2 jumper. Reasjust GAIN and Stability aerward 4. Tum off other electrical equipment that may be causing interference RReacjust the GAIN and STABILITY 2._Adjust the DEAD TIME COMPENSATION by adding a capacitor from posts E2 to 3 (negative on sow porese AM TEQURy of speed 2), Sart with 10 mF and increase untl instability is eliminates, Telow a ‘check tue! system linkage during engine operavon for 2 binding + high ftion + poor linkage Increasing the GAIN should reduce the instabilly but not totally correct IF this is the case, there is most key a problem with the engine ise. Check for: + engine mis-fings NonPeriodic Erratic Engine Behavior + erratic fuel system + Toad changes on the generator set voltage regulator I thatteis slighty erratic, but performance is fast, move switch C1 to the OFF position, ESDSSO0E Series Speed Conto! Unit 3-2020-€1 [PIB 1002: ‘Governors America Corp. © 2020 Copyright All Rights ReservedTROUBLESHOOTING (CONTINUED) UNSATISFACTORY PERFORMANCE ‘SYMPTOM Engine ‘overspeed ‘Actuator does not ‘energize fly Engine remains below desires govemed speed CHECK Do Not Crank. Apply DC Power fo the governor system Manually hold the engine ‘al the desired running speed. Measure the DC voltage between Termi- nals Al-)&F(+) onthe ‘speed contol unit, Measure the voltage at the battery while cranking Momentary connect Terminale Aand F. The ‘actuator should move fo ‘the fl fuel postion Measure frequency of magnetic speed pickup (or calculate), Measure the actuator output Terminals & Bile ning under ‘governor cont. PROBABLE CAUSE 41. Alter the actuator goes to ful ue, disconnect the speed sensor at Terminal Cand D. Ifthe actuator Is silat ful ue-sped then the speed control unit is defective. 2. Ifthe actuator is at minimum fuel position and there exists an erroneous position signal, then check speed sensor cable. Inthe voltage reading is 1.0 0 15 V DC: SPEED agusiment is set above desired speed + Defective speed control unit I voltage reading is above 1.5 V DC then check for: = actuator binging + inkage binding ithe voltage reading is bolow 0.8 V DC: + "Defective speed contol unit the voiage i ess than: oT ora 12 system, of + 14V fora 24V Systom, Then: Check or replace baton. 1. Actuator or batory wing in error 2. Actuator or linkage binding 3. Defective actuator I above 7000 He then add jumper to Terminal G and J. 1. fvottage measurement is within 2V DC of the battery supply voltage level, then fuel conto is restricted from reaching fl fue! postion, possibly de to mechanical governor, carburetor spring, or Tnkage intertorence 2. SPEED parameter set too low ESDSSO0E Series Speed Conto! Unit 3-2020-€1 [PIB 1002: ‘Governors America Corp. © 2020 Copyright All Rights Reserved