EG2000

Generator Electronic Governor Controller

Operation Manual

Smoke Limit Control, Idle Speed Control, suitable for Built-in,

Non-Built-in and PT Pump Type Actuator

Headquarters : No.3, Lane 201, Chien Fu ST., Chyan Jenn Dist., Kaohsiung, TAIWAN
Tel : + 886-7-8121771 Fax : + 886-7-8121775 URL : http://www.kutai.com.tw
 1. SPECIFICATIONS
1.1 Electronic Specifications
Operating Voltage MPU input signal
12 or 24 VDC ±20% 1 ~ 120VAC RMS

Output Current Droop

0.5 ~ 15 A 4%

Run Speed Adjustment range Adjustment

Speed adjustment Potentiometer (30 turn) Run Speed, Idle Speed,
4 Segment Dip Switch Adjustable From 600 ~ 9500 Hz. Ramp Time, Droop, Gain, Integration

Idle Speed Adjustment Range Mechanical Vibration

Run Speed 30 ~ 85% 1G @ 18 ~ 30 Hz, 2.5G @ 48 ~ 70 Hz

Ramp Time Relative Humidity

< 95%
3 ~ 20 Sec
Operating Temperature
Remote Speed Pot
-40 ~ 85℃
Ext. Remote speed pot terminal 6, 7, 8 (ILS) and 6, 7, 9
connect a 5KΩ potentiometer ±5% adjustment range. Storage Temperature
-40 ~ 85℃
Temp. Stability
<0.01% Dimensions
147mm L * 114mm W * 50mm H
Run Speed Stability
± 0.25 % at steady state Weight
690g ± 2%

2 Function Descriptions 2.2 Installation Descriptions

The EG2000 provides both an adjustable Idle 1. Protect the EG2000 by installing it inside the
Speed and ramp, for controlling engine smoke, engine instrument control panel.
vibration and warm-up.
2. Mount the Actuator close to the engine fuel
2.1 Controller system. See actuator manufacture instructions.

Together, the EG2000 Controller, Actuator and 3. Always choose a point on the actuator control
MPU (Magnetic Pickup) form the electronic engine arm in which it can rotate freely, providing
governor assembly. minimum and maximum fuel (But do not bottom
out the actuator; leave 2 to 3 degrees before the
The EG2000 receives the signal from the MPU and, off and on position).
depending on the engine RPM, the actuator controls
the fuel intake on the engine. 4. Use a Non-Linear link on Gas engines to get low
Gain at light loads and high Gain at heavy loads
The EG2000 receives its power from the engine and a linear link on diesel ejection pumps.
batteries or an AC to DC power supply rated from 12
or 24 VDC ±20% matching the Actuator voltage.
The average operating current is around 2.5 to 3.5
amps, but it may reach 15 Amps during engine start
or sudden load changes.

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2 EG2000
5. Mount the magnetic pickup on the flywheel bell 4. OPERATION
housing to count the teeth on the ring gear. The
teeth are converted to an electrical pulse by the 4.1 Idle Speed and Smoke Limiting
MPU. These pulses are cross referenced with the Adjustment The EG2000 has two
original setting on the EG2000. Any difference is
settings used for smoke limiting :
used by the actuator to change engine RPM to
maintain the same pulse count.
1. Idle Speed

3. CONNECTION The setting of the lowest engine operating speed.

• Before firing the engine, adjust the Idle Speed to
Terminal the maximum, and Ramp Time to the minimum.
1, 2 DC Power Input
• Adjust Run Speed to minimum and let Terminal 2
2, 3 IDLE Terminal & 3 be Open Circuit.
4, 5 For ACT, Max @ 15A
• Start engine. The engine speed may rev to Run
6, 7, 8 Remote speed control. Speed right away. Slowly adjust Run Speed to
Connect 5KΩ potentiometer approx. the rated generator RPM.
6, 7, 9 ±5% adjustment range.
• Short Terminal 2 & 3 the engine speed should
10, 11 MPU input, Ground Terminal No. 10 drop, slowly set Idle Speed to a comfortable
engine idle.
1. Terminal 1 & 2 used for DC power input. Terminal
• Stop engine and adjust Ramp. Time to it center
1 for Positive (+) and Terminal 2 for Negative (–)
setting then restart engine. At this time, the
input -Voltage can be 12/24VDC ±20%.
engine speed will stay in Idle and slowly Ramp up
2. Terminal 2 & 3 are the IDLE SW. Terminal when to normal engine speed. Adjust to preferred
2 & 3 open normal Run Speed, When Terminal 2 Ramp speed. Refer to Figure 1.
& 3 shorted engine in Idle.
• When operating at normal RPM closing the IDLE
3. Terminal 4 & 5 is the output terminal for the SW, decreases engine RPM back to idle RPM
actuator, providing a maximum of 15A. according to preset Ramp Time.
4. Terminal 6 and 7-8 and terminal 6 and 7-9 are • To ensure positive engine starts every time follow
two sets of remote speed control. Referring to step (4) and turn the Idle Speed potentiometer an
figure 4, connect a 5KΩ potentiometer, and turn additional 3 to 5%.
the knob to central position. Let engine run on
Run Speed to adjust to the rated engine speed, 2. Ramp Time.
the adjustable range is ±5%. Users can also
• On hot engines, a specific fuel limit setting will
series a resistor to the potentiometer variable
control start-up smoke, but not completely. A hot
point to either terminal 8 or 9 to narrow the
engine does not need the same fuel limits to start
adjustable range. The wirings used to connect to
as a cold starting engine.
terminal 6, 7-8 and 6, 7-9 must use the 3-wire
shielded cable. The drain shield wire is to be • Ramp Time can be set from 3 up to 20 seconds.
connected to terminal 10 and the other end of the The Ramp Time is the length of time from Idle to
drain shield wire must cut off and taped. the rated Run Speed.
5. Terminal 10 and 11 is the MPU signal input
terminal. The wiring used to connect to the
terminals must use a 2-wire shield cable. The
drain shield wire is to be connected to Terminal
10 and the other end of the drain shield wire must
cut off and taped.
6. Harness used to connect to Terminal 1, 2, 4 and
5 must use the 2.0mm twist pair harness.

Figure 1
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EG2000 3
4.2 Isochronous Adjustment 4.4 Remote Speed POT Adjustment
Isochronous operation is obtained by setting Droop EG2000 is equipped with 2 sets of Remote Speed
potentiometer fully counterclockwise. EG2000 is Potentiometer adjustment. By adding a 5KΩ
normally operated in the isochronous mode; i.e., Potentiometer, user can adjust the engine speed
engine RPM is constant (±0.25%), under steady from as far as 60 meters away from the engine.
state load conditions, up to the engine’s maximum Please refer to Figure 4 for connection. To narrow
capability, regardless of load on the engine. Please the adjustment range, series a resistor on either
refer to Figure 2. Terminal 8 or 9 to reduce. Without the resistor the
adjustment range is approximately 5%.

4.5 Gain, I (Integration), Adjustment

1. Shutdown engine and DC input turned off.
2. Potentiometer original setting.
3. Adjust INT., Gain and Ramp Time Potentiometer
to minimum setting (Fully Counterclockwise)
4. Under Isochronous operation, set Droop
potentiometer fully counterclockwise.
5. Set the MPU frequency range :
Figure 2
Select the suitable frequency setting according to
4.3 Non-isokinetic Operation the highest engine frequency range

When operated under Non- isochronous (Paralleled), Input Signal Frequency :

Droop is used to distribute the actual power from the
generators. Please refer to Figure 3. RPM × Flywheel teeth
60 sec
Droop operation is obtained by setting the Droop
potentiometer. Moving Droop Pot clockwise
increases the Droop. The amount of Droop for a Frequency Selection
given setting depends on the magnetic pickup
frequency and no load to full load actuator shaft SW-1 ON 600 ~ 1200Hz
rotation. SW-2 ON 1200 ~ 2500 Hz
SW-3 ON 2500 ~ 5000 Hz
SW-4 ON 5000 ~ 9500 Hz
(If uncertain Set SW3-ON and the balance to OFF)
6. Idle Speed set to maximum, Run Speed set to
minimum
7. Adjust Remote Speed POT to central (If used)
8. Start Engine
At this time the engine should rev to Run Speed, (If
engine speed exceeds its rated speed, Stop engine
Figure 3 and immediately choose a lower frequency setting)
slowly adjust Run Speed pot clockwise to the rated
engine speed.
A Droop potentiometer setting of 10 o’clock will give
about 4% Droop, no load to full load when the For Idle Speed, Ramp Time And Idle Sw Setting,
pickup frequency is 4260Hz and actuator shaft Reference To Paragraph 4.1
rotation is approximately 30 degrees from no load to 9. Slowly adjust Gain clockwise until the actuator
full load. Lower pickup frequency or smaller shaft begins to oscillate.
rotation results in less Droop for the system.

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4 EG2000
10.Slowly adjust Gain counterclockwise until it 14.Again manually adjust the linkage. If the linkage
becomes stable. begins to oscillate 3 to 5 times and then
stabilizes, then the setting is complete.
11.Manually move the linkage. If the linkage
oscillates 3 to 5 times and then stabilizes, then • Please reference from 4.2 and 4.3 for Droop
the setting is correct. setting.
12.If engine speed overly increases or decreases Note 1：If GAIN or INT. (Integration) is over adjusted,
when adding load or reducing load, please adjust it causes the engine speed to oscillate.
the Gain VR clockwise a little. Repetitively increasing and decreasing the
GAIN and INT. arrangement can help to
13.If engine speed recovers too slowly, adjust INT.
obtain the best performance.
(Integration) clockwise, in the same time
decrease the GAIN setting. Observe the actuator Note 2 ： Due to different types of external and
linkage. If the linkage is stable, manually adjust internal built-in type actuators, the
the linkage. If the linkage slowly oscillates, then adjustment of Gain is very important,
the response time is inadequate. Adjust INT. together with INT. (Integration) adjustment.
counterclockwise until the response is improved. In PT pump type actuators, the movement is
very limited, so Gain is set to the minimum
using INT. (Integration) to adjust engine
speed compensation.

5. DIMENSION AND TYPICAL WIRING DIAGRAM

DROOP INT. GAIN RAMP-TIME

SW

POWER : DC12/24V
SW1-ON 600~1200HZ
SW2-ON 1200~2500HZ
SW3-ON 2500~5000HZ
SW4-ON 5000~9500HZ

IDLE SPEED
REMOTE
SPEED POT RUN SPEED
+ IDLE ILS
~
ACT
1 2 3 4 5 6 7 8 9 10 MPU 11

Idle Cable A
switch
Cable B

R Magnetic
Pickup
_
+
DC Power CCW
Actuator
5K Wiring Drawing
CW
Figure 4

* Cable A, B - use a cable with a wrapped Mylar 1. To connect the DC power supply and actuator
aluminum foil shield with a drain wire. use a 12 AWG / 2mm twist pair harness.
* To connect the 5KΩ potentiometer, refer to 2. Connect the MPU to the EG2000 using a 2-wire
paragraph 3. Connections. shielded cable. Anchor the drain shield wire to
Terminal 10 and the other end cut and tape off.

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EG2000 5
5. TROUBLESHOOTING
PROBLEM CORRECTIVE ACTION
Actuator goes to full stroke 1. Check magnetic pickup leads for proper shielded wire or open shield.
when DC power is turned on Verify and correct wiring as necessary. Be sure there is no jumper
(Engine is not operating) between terminals 2 and 3.
2. Failsafe circuit in the controller may be damaged or defective. Replace
with new controller.
3. With DC power OFF remove leads at actuator. Check continuity of
conduction on each terminal to case. There should be no continuity of
conduction between any terminal and case of EG2000. If conduction
is measured, please replace the controller.
4. If remote speed potentiometer has been connected to terminals 6, 7
and 9 of the controller, disconnect these leads. Turn DC power ON to
the governor if the actuator is now normal. Proceed to corrective
actions for the next problem.
Governor is completely dead 1. Check battery voltage at terminals 1 and 2 on controller. Terminal 1 is
and actuator lever stays at positive. Check battery connections and contacts for turning power
minimum position when power ON to the controller.
is applied to governor. 2. Check for proper linkage setup. Correct and free linkage.
3. Magnetic pickup signal absent or too low. Measure AC voltage across
terminals 10 and 11 while cranking the engine. Voltage should be min.
1.0 VAC.

NOTE:
The voltmeter should have an impedance of 5000 ohms / volts or
higher. Check pole tip gap over gear tooth. Should be 0.037 mm ~ / -
0.127 mm.
4. Measure the resistance of the magnetic pickup coil. This should be
above 50 ohm. If there is an open or shorted coil, replace the
magnetic pickup.
5. Measure the resistance of each pin to the metal case of the magnetic
pickup. No continuity should be evident.
6. If there is continuity of conduction to the case, replace with new
magnetic pickup.
7. Measure actuator coil resistance:
If actuator coil is open or shorted to case, replace the actuator.
If governor still does not operate, continue with steps below.
8. Measuring the resistance of each coil lead to the actuator case should
indicate an open circuit on a low scale of the ohm meter. If continuity is
defected, replace the actuator.
9. With DC to the governor ON and the engine OFF, measure the DC
voltage from terminal 6(+) to terminal 2(-). This should be approx.
4VCD. If 4 VCD is not present, replace the controller.
10.Between terminal 7(+) and terminal 2(-), the voltage should be
approx. 4.6 VDC. If 4.6VDC is not present, replace the controller.

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6 EG2000
 PROBLEM CORRECTIVE ACTION
Erratic governor operation 1. Measure DC voltage at 1 and 2 on controller terminal strip. Normal
battery voltage should be indicated. If nominal voltage is present,
wiring is correct.
2. Low battery voltage 20% below rated can cause erratic operation.
Check battery and charging system.
3. RFI noise due to incorrect shielding. Correct wiring.
4. RFI noise fed through power supply leads. Connect power leads
directly to the battery.
Improper operation from 1. Investigate wiring to remote speed potentiometer for open or shorted
remote speed potentiometer circuits. Checking wiring.
2. If the leads at terminals 6 and 7 to the remote speed potentiometer are
reversed, speed control by the remote speed potentiometer will be
reversed. Correct wiring.
3. Lead wire to remote speed setting potentiometer should be 3-wire
shielded cable. Verity that the drain shield wire is isolated from ground
at the potentiometer. If terminal 6 lead to the remote speed
potentiometer is open, engine speed will go high. Correct the wiring.
4. If lead 8 and 9 (wiper lead to remote potentiometer) is open, there will
be no control by the remote speed potentiometer. Verify and correct
wiring.
5. If lead 7 to the clockwise terminal of the remote speed potentiometer
is open, speed will remain at the value set in EG2000.
Slow, small amplitude hunting
Jammed or very loose linkage. Correct linkage.
of speed or frequency
Fast oscillation of governor
Verity calibration setting of the controller. Readjust setting as necessary.
linkage
Engine will not start – Actuator 1. Make sure fuel is available. Check fuel to engine.
goes to full fuel during cranking Check for correct wiring to the automatic shutdown circuits.
2. Air may be trapped in fuel line. Check fuel lines for leaks.
3. Try to operate engine manually.

※ Please accept our sincere apology if any modification in performance, specification or appearance is
made without prior notice.

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EG2000 7