ESD5500E Series

Speed Control Unit

1 INTRODUCTION
The ESD5500E Series Speed Control Unit is an all-electronic device designed to control
engine speed quickly and precisely in response to transient load changes.

The ESD5500E controls a wide variety of engines in isochronous or droop mode when
connected to a proportional electric actuator and magnetic speed sensor. The ruggedly
built ESD5500E series is designed to withstand the engine environment. Light-Force
variations are available.
MODEL DESCRIPTION
ESD5500E Multi-V DC / Standard Unit
Multi-V DC / Light-Force (Low-Current Optimized PID) / Enhanced
ESD5520E Droop
Multi-V DC / Light-Force (Low-Current Optimized PID) / Enhanced
ESD5522E Droop for Cummins EFC Forward Acting (Normally Closed)
Multi-V DC / Light-Force (Low-Current Optimized PID) / Anti-Windup
ESD5526E Circuit (Gaseous) / Recommended for T1/T2 ATBs
Multi-V DC / Anti-Windup Circuit (Gaseous) / Recommended for T3/T4
ESD5528E ATBs

2 SPECIFICATIONS
Performance RELIABILITY
Isochronous Operation ± 0.25 % or better Vibration 1 g @ 20-100 Hz
Speed Range / Governor 1 - 7.5 kHz Continuous
Testing 100 % Functionally Tested
Speed Drift with Temperature ±1 % MAX
Environmental
Idle Adjust Clockwise 60 % of Set Speed
Ambient Temperature -40° to 85 °C [-40° to 180 °F]
Idle Adjust Counterclockwise Less than 1200 Hz
Relative Humidity up to 95 %
Droop Range 1 - 5 % regulation
Droop Adjust Maximum 400 Hz ±75 Hz per 1.0 A change All Surface Finishes Fungus Proof, Corrosion Resistant
(K-L jumpered)
COMPLIANCE / STANDARDS
Droop Adjust Minimum 15 Hz ±75 Hz per 1.0 A change
(K-L jumpered) Agency CE (EN55011, EN50081-2, EN50082-2),
RoHS, Lloyds Register,
Speed Trim Range ± 200 Hz DNV/GL, Bureau Veritas
Remote Variable Speed 500 - 7.5 kHz PHYSICAL
Range
Dimension See Wiring Diagram and Outline
Terminal Sensitivity
J 100 Hz ±15 Hz/Volt @ 5.0 kΩ Impedance Weight 1.20 lbf [0.54 kgf]
L 735 Hz ±60 Hz/Volt @ 65.0 kΩ Impedance
N 148 Hz ±10 Hz/Volt @ 1 MΩ Impedance Mounting Any position, vertical preferred
P 10 V DC Supply @ 20 mA MAX
Input / Output
DC Supply 12 V DC and 24 V DC Battery Systems
Transient and Reverse Voltage Protected*
Polarity Negative Ground (Case Isolated)

Power Consumption 50 mA continuous plus actuator current

Speed Signal Range 1.0 - 50 V AC

Speed Sensor Signal 1.0 - 120 V RMS
Actuator Current Range** Minimum 1.0 A
(77°F (25°C)) Nominal 7.0 A
Peak 10.0 A

* Protected against short circuit to actuator (shuts off current to actuator), unit automatically turns on when short is removed.
** Protected against reverse voltage by a series diode. A 15 A fuse must be installed in the positive battery lead.

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3 Installation & Outline Diagram

READ THIS ENTIRE GUIDE BEFORE PER-

FORMING AN INSTALLATION.

Vertical orientation
allows fluids to drain
in moist environ-
ments.

Avoid Extreme Heat

Mount in a cabinet,
engine enclosure, or
sealed metal box.

in
Dimensions
[mm]

4 Wiring

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 4 Wiring (CONTINUED)

An overspeed shutdown device, independent of the governor system, must be provided to prevent loss of engine 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.

When wiring ESD5500E Series controllers:

1. Use shielded cable for all external connections to the ESD controller.
2. One end of each shield, including the speed sensor shield, should be grounded to a single point on the ESD case.
3. Terminal A, B, E,and F should be 16 AWG or larger. Long cables require increased wire size to minimize voltage drops.
4. Battery positive (+) Terminal F should be fused for 15 A.
5. Magnetic speed sensors Terminals C and D must be twisted and or shielded for the entire length.
6. 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 1 V AC RMS during cranking.
7. If auto synchronization is used alone, not with a load sharing module, use a 3 Ω 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.
9. 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 in this terminal can damage the speed control unit.
10. Do not over-tighten terminals. Torque to no greater than 9.0 in-lb ±2.5 [1.01 ±0.28 N∙m].

TERMINAL DEFINITION NOTES

A&B Actuator (+/-) 16 AWG [1.3mm2] or larger wire

• Wires must be twisted and/or shielded for their entire length
Magnetic Speed Pickup
C&D • Gap between speed sensor and gear teeth should not be smaller than 0.02 in. (.51mm)
(D is ground)
• Speed sensor voltage needs to be at least 1 V RMS during crank
• 16 AWG [1.3mm2] or larger wire
E&F Battery Power (-/+) • A 15 A fuse must be installed in the Positive battery lead to protect against reverse voltage
• Battery positive (+) input is Terminal F
G Ground Signal
H For 12 V systems with actuator currents above 5 A, may sometimes require a jumper between Terminals H and G
J Variable Speed 5 kΩ resistive nominal.
K&L Droop Select Active when closed
M Idle Select Close for Idle
N Accessory Input Load Sharing/Synchronizing, 0-10 V DC (5V Nominal, Reversed, 148 Hz/V). Shielded cabling recommended.
P Accessory Power Supply 10 V DC Output To Power GAC Load Sharing and Synchronizing Modules

ADDING A POTENTIOMETER

Install a single remote speed adjustment potentiometer (speed trim

control) to adjust engine speed. Select the desired speed range and the
corresponding potentiometer value. If the exact range is not found select
the next higher range potentiometer.

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 5 ADJUSTMENTS BEFORE ENGINE STARTUP
Make sure the following adjustments are set before starting the engine.

GAIN Middle Position

STABILITY Middle Position
SPEED TRIM CONTROL Middle Position
STARTING FUEL Full CW (MAX fuel)
SPEED RAMPING Full CCW (fastest)

6 Start The Engine

The speed control unit governed speed setting is factory set at approximately engine idle speed. (1000 Hz., speed sensor signal or 600 RPM)
If the engine does not start, adjust the speed potentiometer clockwise.

Crank the engine with DC power applied to the governor system. The actuator will energize to the maximum fuel position until the engine
starts. The governor system should control the engine at a low idle speed. If the engine is unstable after starting, refer to Section 8 ADJUST-
ING FOR STABILITY.

7 Governor Speed Setting

The governed speed set point is increased by clockwise rotation of the
SPEED adjustment control. Remote speed adjustment can be obtained
with an optional 5 kΩ Speed Trim Control potentiometer.

IMPORTANT:
Speed Adjustment Is a 25
Turn 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
engine stability.

NOTE
Normally, adjustments made at no load achieve satisfac-
tory performance. If further performance improvements
are required, refer to Section 12 TROUBLESHOOTING.

PARAMETER PROCEDURE
GAIN 1. Rotate the GAIN adjustment clockwise until instability develops.
2. Gradually move the adjustment counterclockwise (CCW) until stability returns.
3. Move the adjustment one division further counterclockwise to ensure stable performance (270° potentiometer).
4. If instability persists, adjust the next parameter.

STABILITY Follow the same adjustment procedure, steps 1 - 3, as the GAIN parameter.

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 9 Starting Fuel Adjustment

The engine’s exhaust smoke at start-up can be minimized by complet-

ing the following 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 appli-
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. Increase the STARTING FUEL slightly so that the idle
speed is returned to the desired level.

4. Stop the engine.

10 METHODS OF OPERATION
One of two methods of operation for the ESD5500E may be selected: Operating Speed or Idle.

METHOD 1 - Operating Speed METHOD 2 - IDLE SPEED

Start the engine and accelerate directly 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
the starting process so that each may be optimized for the lowest
PROCEDURE 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 from idle to rated speed.
1. Replace the connection between Terminals M & G with a tog-
3. If the starting time is too long, the STARTING FUEL may need to gle switch or a normally open water jacket temperature switch.
be adjusted slightly clockwise (CW). Other optical switch combinations can be used.

2. Start the engine.

3. If the starting smoke is excessive, the STARTING FUEL may

need to be adjusted slightly CCW.

4. If the starting time is too long, the STARTING FUEL may need
to be adjusted slightly CW.
Full CW = MAX Fuel Full CCW = Fastest 5. When the switch opens, adjust the SPEED RAMPING for the
least amount of smoke when accelerating from idle speed to
rated speed.

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 11 Additional Features and Optional Wiring

Idle Speed Setting

If the 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
applies droop to the governor system to ensure stable operation.

If not using the idle method, you can lower idle to the bare minimum (even if it’s
not being used) for smoke reduction.

Lead Circuit & Soft Coupling

Switch 1(C1) controls the Lead Circuit. The normal position is IDLE
ON.
Move the switch to the OFF position if there is fast instability in the
system. C1 OFF ON C2 IDLE
LEAD CIRCUIT SOFT COUPLING
ON OFF
Switch 2(C2) controls a circuit designed to eliminate fast erratic gover-
nor behavior, caused by very soft orSPEED
worn couplings in the drive train LEA

between the engine and generator.

SPEED
DROOP
The normal position is OFF. Use the ON position if you experience
fast erratic engine behavior between the engine and generator due to DROOP
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-
cessories are directly connected to this terminal.
NOTE Terminal N is sensitive (145 Hz/V). Accessory connections
must be shielded.
2750 Hz x 60 seconds = 1500 RPM
When an accessory is connected to Terminal N, the speed will de- 110 Teeth
crease and the speed adjustment must be reset.

If the auto synchronizer is used alone, not in conjunction with a load shar-
ing module, a 3 Ω 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.

Accessory Supply

The +10 volt regulated supply, Terminal P, can be utilized to provide power to GAC governor system accessories. Up to 20 mA of current can
be drawn from this supply. Ground reference is Terminal G.

A short circuit on this terminal can damage the speed control unit.
Do not connect Terminals N and P directly to each other.

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 11 Additional Features & Optional Wiring (CONTINUED)
Remote Variable Speed Operation
A single remote speed adjustment potentiometer is added to adjust the engine speed continuously over a specific speed range.

Select the desired speed range and corresponding potentiometer value (See Variable Speed Table). If the exact range cannot be found, select
the next higher range potentiometer.

To maintain engine stability 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
NOTE range potentiometer using Terminals G and J. Contact GAC for assistance if you experience difficulty obtaining the desired
variable speed governing performance.

VARIABLE SPEED TABLE

SPEED FREQUENCY RANGE POTENTIOMETER VALUE
900 Hz 1 kΩ
2400 Hz 5 kΩ
3000 Hz 10 kΩ
3500 Hz 25 kΩ
3700 Hz 50 kΩ

Conversion Formulas
(RPM x #Teeth) (HertzMAG PICKUP x 60)
HertzMAG PICKUP = RPM =
60 #Teeth

The ESD5500 series of controllers have the ability to expand the speed range by placing a jumper wire across terminals
G and J. The standard range is 7400 Hz however this is based on the operating speed and the number of flywheel teeth
NOTE
(see formula). If your application is above this frequency, or near it – place the jumper and test again. This is an important
step if your engine is not able to reach rated speed but the actuator is not 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 full load.

Place the optional external selector switch in the DROOP 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.

Though a wide range of droop is available with the internal control, droop level requirements of 10% are unusual. If droop
NOTE levels experienced are higher or lower than those required, contact GAC for assistance.

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 12 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 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 F(+) & E(-) Voltage 2. Low battery voltage
(12 or 24 V DC)
3. Wiring error
1. Gap between speed sensor and gear teeth too great. Check Gap.

1.0 V AC RMS min. while 2. Improper or defective wiring to the speed sensor. Resistance between D and C should be 160 to
2 C(+) & D(-)
cranking 1200 Ω. See your specific mag pickup data for resistance.

3. Defective speed sensor

1. Short on Terminal P
3 P(+) & G(-) 10 V DC, Internal Supply
2. Defective speed control unit
1. SPEED potentiometer set too low

2. Short/open in actuator wiring

1.0 - 2.0 V DC while
4 F(+) & A(-)
cranking
3. Defective speed control

4. Defective actuator, see your actuator manual for troubleshooting information.

Insufficient Magnetic Speed Signal

A strong magnetic speed sensor signal eliminates the possibility of missed or extra pulses. The speed control unit will govern well with 1.0 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 0.02 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 set to OFF.

The engine seems to jitter 2. Readjust the GAIN and STABILITY for optimum control.
Fast Periodic with a 3 Hz or faster irregu-
larity of speed. 3. Remove the E1 to E2 jumper. Readjust GAIN and Stability afterward.

4. Turn off other electrical equipment that may be causing interference.

1. Readjust the GAIN and STABILITY

2. Adjust the DEAD TIME COMPENSATION by adding a capacitor from posts E2 to E3 (negative on
E2). Start with 10 mF and increase until instability is eliminated.
An irregularity of speed
Slow Periodic
below 3 Hz.
Check fuel system linkage during engine operation for:
• binding
• high friction
• poor linkage
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:
• engine mis-firings
Non-Periodic Erratic Engine Behavior • erratic fuel system
• load changes on the generator set voltage regulator

If throttle is slightly erratic, but performance is fast, move switch C1 to the OFF position.

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12 Troubleshooting (CONTINUED)

Unsatisfactory Performance
SYMPTOM CHECK PROBABLE CAUSE
1. After the actuator goes to full fuel, disconnect the speed sensor at Terminal C and D. If the actuator
1. Do Not Crank. Apply DC is still at full fuel-speed then the speed control unit is defective.
power to the governor
system. 2. If the actuator is at minimum fuel position and there exists an erroneous position signal, then check
speed sensor cable.
If the voltage reading is 1.0 to 1.5 V DC:
Engine • SPEED adjustment is set above desired speed
Manually hold the engine
Overspeed • Defective speed control unit
at the desired running
speed. Measure the DC
If voltage reading is above 1.5 V DC then check for:
2. voltage between Termi-
• actuator binding
nals A(-) & F(+) on the
• linkage binding
speed control unit.
If the voltage reading is below 0.8 V DC:
• Defective speed control unit
If the voltage is less than:
Measure the voltage at
1. • 7V for a 12V system, or
the battery while cranking.
• 14V for a 24V system, Then: Check or replace battery.

Momentarily connect 1. Actuator or battery wiring in error

Actuator does not Terminals A and F. The
2. 2. Actuator or linkage binding
energize fully actuator should move to
the full fuel position.
3. Defective actuator
Measure frequency of If above 7000 Hz then add jumper to Terminal G and J.
3. magnetic speed pickup
(or calculate).
1. If voltage measurement is within 2 V DC of the battery supply voltage level, then fuel control is
Measure the actuator restricted from reaching full fuel position, possibly due to mechanical governor, carburetor spring, or
Engine remains
output, Terminals A & linkage interference.
below desired 1.
B, while running under
governed speed
governor control. 2. SPEED parameter set too low

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 120 Series
Electric Actuator

1 SELECTION CHART
The 120 Series Electric Actuator is a rotary-output, proportional servo.
This electromechanical actuator is used as an engine fuel control posi-
tioning device. An internal spring provides fail-safe operation by forcing
the actuator to the fuel shutoff position when the actuator is de-ener-
gized.

Provides fast operation, multi-voltage usage, and proven reliability.

The actuators can operate directly on 12- or 24- V DC battery supplies.
Ideal for fuel systems on engines up to 150 HP.

◊ Small size
◊ Low Cost
◊ 1.0 lb-ft of torque
◊ Proven Reliability
◊ 25° Rotation
◊ Low Friction

System Voltage Connector

Model Shaft Housing
12 24 Multi MIL Commercial Packard
ACB120 Serrated Sand cast
ADB120 Serrated Die cast
ADC120S-12 Serrated Die cast
ADC120S-24 Serrated Die cast
ADD120S-12 Serrated Die cast
ADD120S-24 Serrated Die cast

2 SPECIFICATIONS
PERFORMANCE
Available Torque 1.0 ft-lb max (1.4 N m) ACTUATOR AVAILABLE TORQUE
Max Operating Shaft Travel 25 ° ±1 ° CW/CCW
Graph of Actuator Torque
POWER INPUT
1.0
Operating Voltage 12 or 24 V DC ADB/ADC
INCREASE

Normal Operating Current 2.0 A @ 12 V DC FUEL

1.0 A @ 24 VDC
Maximum Current 6.0 A @ 12 V DC
Continuously Rated 3.0 A@ 24 V DC TORQUE .5
(Lb.-Ft.)
ENVIRONMENT ADB/ADC
DECREASE FUEL
Operating Temperature Range -65 °F to +200 °F (-54 °C to +95 °C) (SPRING)

Relative Humidity up to 100 %

All Surface Finishes Fungus Proof and Corrosion Resistant
0
PHYSICAL 0 5 10 15 20 25
ANGLE (Deg.)
Dimensions See Section 3, Outline & Dimensions
Weight 4.5 lbf (2.05 kgf)
Mounting Electrical connector at top preferred
RELIABILITY
Vibration Up to 20 g, 50 - 500 Hz
Testing 100% Tested
1 120 Series Electric Actuator 5-2020-B1 PIB2010 10
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 3 Outline & dimensions

ACB120

Dimensions
in
[mm]

ADC120

Dimensions
in
[mm]

2
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 3 Outline & dimensions (CONTINUED)

ADB120

For the ADB120E4 with built-in fuel metering valve for Cummins PT fuel sys-
tems, see your GAC representative for more information.

ADD120

Dimensions
in
[mm]

3 120 Series Electric Actuator 5-2020-B1 PIB2010 12

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 4 Installation
The following installation rules must be taken into account when mounting the 120-series.

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 shutoff device, such as a fuel solenoid must be used.

1. The actuator must be rigidly mounted as close as possible to the fuel control lever of the engine. Vibration from the engine will not
affect the operation of the actuator.
2. The preferred mounting is with the electrical connector at the top. Applications with the actuator upside down, on its back, or side-
ways should be avoided.
3. Linkage arrangement of any actuator system is always important. High quality rod end bearings should be used. Rod end bear-
ings that have high friction can cause instability and require servicing. Levers and linkage should be sturdy yet low in mass for the
fastest speed of response.
4. Arrangement of the linkage (linear or non-linear) for actuation of the engine fuel control is an important application consideration.
a. For proportional actuators operating in linear control systems (See FUEL LEVER AT MID FUEL POSITION DIAGRAM below)
it is important to obtain a linear relationship between actuator stroke and fuel delivery. The linkage configuration for diesel fuel
systems is typically as shown in MID FUEL. The lever on the actuator should be nearly parallel to the pump lever at the mid fuel
position for linear fuel control.
b. For proportional actuators operating in non-linear systems (See FUEL LEVER AT FULL FUEL POSITION DIAGRAM below), it
is important to obtain a non-linear relationship between actuator stroke and fuel delivery. Carbureted, PT Pumps (CUMMINS),
or other non-linear fuel systems require a non-linear fuel linkage configuration as shown as FULL FUEL. A non-linear fuel
system results when more engine power is developed for a given stroke at positions of low fuel settings rather than at high fuel
settings. In this case the levers should be parallel at full load.
5. In general, adjust the linkage so that the fuel control lever minimum and maximum fuel stops are used rather than the actuator
internal mechanical stops. The actuator should be adjusted so that it operates over at least one half (12 degrees) of its available
travel. For the ADB120E4 with built-in fuel metering valve for Cummins PT fuel systems, see your GAC representative for more
information.

FUEL LEVER AT MID FUEL POSITION DIAGRAM FUEL LEVER AT FULL FUEL POSITION DIAGRAM

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 5 Wiring
Wiring is dependent on the actuator connector type. For more information see your GAC representative.

Prewired for 12 or 24 V. Mating hardware included (Commer-

ADC
cial).
CH1215 Packard Cable Harness
ADD
EC1300 Packard Mating Half
ACB CH1203 - 12’ Military Straight Harness
CH1210 - 12’ Military 90° Harness
ADB CH1212 - 30’ Military Straight Harness
EC1000 Military Straight Connector PACKARD COMMERCIAL MILITARY
EC1010 Military 90° Straight Connector CONNECTOR CONNECTOR CONNECTOR

The mating electrical connector must be wired in a configuration

AB AB
dependent on the system voltage supply.
4.3 OHMS

The maximum wire size that will fit into the actuator mating half F A

connector is 16 AWG (1.3 mm sq.). E

B

D C

Cable CH1203/1210, a pre-wired actuator cable harness, is 12 3.4 OHMS

ft (4 m) in length and suitable for use on 12 or 24 V systems.

CH1212 is 30 feet (9.1 meters) in length.

Actuator cable harnesses with lengths greater than 10 ft (3 m)

from the actuator to the speed control unit may introduce cur-
rent losses which can restrict full rotation of the actuator. In this
case, use of a larger gauge wire is required. For applications
where EMI is of concern, twisted, shielded cable for the actuator
is recommended. Twisting of the cable alone will substantially
reduce EMI.

FOR 12 V APPLICATIONS It is preferable to connect four wires, to Actuator Terminal “A”

one to each of the coils and wire. Maximum current is 8 A. The on Speed Control Unit
recommended wire size is at least 16 AWG (1.3 mm sq.).

A
F B

E C
D

to Actuator Terminal “B”

on Speed Control Unit

FOR 24 V APPLICATIONS A simple jumper wire between pins to Actuator Terminal “A”
B and C at the mating half connector can be made. The remain- on Speed Control Unit
ing two pins, A and D, can be extended to the required length.
Maximum current is 4 A. The recommended wire size is at least
A
18 AWG (1.0 mm sq.). F B
Jumper B to C
E C
D

to Actuator Terminal “B”

on Speed Control Unit

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 6 Adjustments
Once installed, reconfirm that the linkage is not binding and that friction is minimal.

Before starting the engine, push the actuator to the full fuel position and release. It should return instantly to the no fuel position without
any binding.

Once the engine has been started, the linkage can be optimized by temporarily inserting an ammeter in one of the wires between the
speed control unit and the actuator or by measuring the voltage across the actuator.

Measure the actuator current or voltage at no load and full load. The range and the starting current or voltage are important for optimizing
the linkage system. Typical values are shown in the following table for 12 V and 24 V systems.

ACTUATOR Starting CURRENT / VOLTAGE RANGE CHART

12 Volts 24 Volts
No Load 1.0 A, 2 V 0.5 A, 4 V
Full Load 2.5 A, 5 V 1.2 A, 10 V

To increase the range of the actuator voltage or current, move the linkage to a lower hole on the actuator lever. A lower range of actuator
current than suggested can cause instability or poor performance.

To increase or decrease the no load current or voltage, adjust the length of the link between the actuator and the engine fuel control.
Smaller angles of actuator travel may improve transient performance, but will reduce available force at the fuel control lever. Allowing the
actuator to operate through at least one half (12°) of its stroke will usually provide near optimum response.

7 TROUBLESHOOTING
If the governor system fails to operate, make the following tests at the actuator mounted connector while moving the actuator through
its stroke.

MEASURING RESISTANCE

ACB / ADB120 ADC / Add 120

Terminals Resistance Terminals Resistance
A to B 4.2 Ω Red to White (12 V) 1.9 Ω
C to D 3.4 Ω Red to White (24 V) 7.5 Ω
A to C ∞ Red to Housing ∞
A to Housing ∞ White to Housing ∞
C to Housing ∞

Energize the actuator to full fuel (follow steps in control unit publication) and manually move the actuator through its range. No binding
or sticking should occur.
If the actuator passes the tests, the problem is elsewhere in the system. Refer to your speed control unit’s troubleshooting section in
the manual.

6
15
120 Series Electric Actuator 5-2020-B1 PIB2010
Governors America Corp. © 2020 Copyright All Rights Reserved
InteliGen 200

Order code: IG3200XXBAA

Controller for parallel gen-set applications

Datasheet
Product description
Comprehensive paralleling Gen-set controller Up to 5 languages in the controller
Parallel operation for up to 32 Gen-sets Configurable Modbus
Direct communication with ECU Support of MODBUS RTU/TCP* or SNMP* v1/v2c
Remote control and monitoring Detailed history with up to 350 events
Flexible, extendable, yet user friendly Load shedding, dummy load capability
Tier 4 Final support
Key features Automatic temperature based cooling/heating
Multiple Island or Single Parallel to Mains applications
Comprehensive Gen-set protections
both in one controller
Multipurpose flexible timers with full calendar
PLC support with PLC Editor and monitor
True RMS measurement
Perfect solution for rental applications:
Low temperature version available (IG3200XXBLA)
Rental timers
*Available with extension module
Geo-Fencing and tracking via WebSupervisor*

Alternative configuration
Application overview
Droop and Emergency droop
Load sharing and VAr sharing via CAN
Wide communication capabilities including

Integrated USB for configuration

Isolated RS485 port on board for Modbus

Integrated USB Host for uploading/downloading

FW/Configuration with USB key
High accuracy of voltage and current measurement
Cloud-based monitoring and control
Active SMS and emails in different languages*

| InteliGen 200 Datasheet | Related HW ver: 1.0.0 | Related SW ver: 1.5.0 | Date of issue: 12/13/2019 16
 Dimensions, terminals and mounting

Note: The final depth of the controller depends on the selected plug-in module – it can vary between 41 mm and
56 mm. Mind also the size of connectors and cables (e.g. in case of RS232 connector, add about 60 mm more
for standard RS232 connector and cable).

InteliGen 200 Datasheet 2 17

 Technical data

Power supply Display

Power supply range 8-36 VDC Type Build-in monochromatic 3.2"
320 mA / 8 VDC Resolution 132 × 64 px
210 mA / 12 VDC
Power consumption Communications
120 mA / 24 VDC
90 mA / 36 VDC USB port non-isolated

RTC battery Replaceable USB Device Non-isolated type B connector

Power terminal max. 4 A w/o USB Host Non-isolated type A connector

Fusing BOUT consumption RS 485 RS485

E-Stop max.12 A 250 / 50 kbps, isolated, nominal
CAN 1 + CAN 2
E-Stop fusing 12 A impedance 120 Ω

Max. Power Dissipation 3.5 W Current measurement

Operating conditions Measurement inputs 3ph Gen current, 1ph Mains

Operating temperature -20 ˚C to +70 ˚C Measurement range 5A

Operating temperature Max. allowed current 10 A

-40 ˚C to +70 ˚C
for Low Temp. version 1.5 % for full temperature range (1 %
Accuracy
Storage temperature -30 ˚C to +80 ˚C from 0 ˚C to 50 ˚C)

Protection degree Input impedance <0.1 Ω

IP 65
(front panel)
E-Stop
25/55°C, RH 95%, 48hours, w/o
Operating humidity Dedicated terminal for E-Stop input
condensation
Physically disconnects binary outputs 1 & 2 from power
5-25 Hz, ± 1.6 mm
Vibration
25-100 Hz, a = 4 g Binary inputs
Shocks a = 500 m/s2 Number 8, non-isolated
Surrounding air temperature rating 70 °C 0-2 VDC close contact
Close/Open indication
Suitable for pollution degree 2 6-36 VDC open contact
Heat radiation 9W
Binary outputs
D+ terminal 6 low current output, non-isolated
Max. output current 250 mA Low current BO 3-8 = 0.5 A
switching to positive supply terminal
Charging fail threshold 80 % of Usupply
2 high current output, non-isolated
Voltage measurement High current BO 1, 2 = 4 A

3ph-n Gen voltage , 3ph-n Mains switching to positive supply terminal

Measurement inputs
277 V / 480 V AC (EU) Analog inputs
Measurement range
346 V / 600 V AC (US/Canada)
Number 4, Resistive
Linear measurement
381 V / 660 V Resolution 0.1 Ω
and protection range
Range 0-2500 Ω
Accuracy 1%
Input impedance 170 Ω
Frequency range 40-70 Hz (accuracy 0.1 Hz)
±2 % from value in range above
Input impedance 0.72 MΩ ph-ph , 0.36 MΩ ph-n Accuracy
±1.5 kΩ in range 2.5-15 kΩ
Voltage regulator output
Magnetic pickup
Protection Isolated
4 Vpk-pk to 50 Vpk-pk in range 4 Hz to 1 kHz
Type max ±10 VDC Voltage input
6 Vpk-pk to 50 Vpk-pk in range 1 to 5 kHz
range
Speed governor output 10 Vpk-pk to 50 Vpk-pk in range 4 to 10 kHz

±10 VDC or 5 V @ 500 Hz, Frequency

Output Type 4 Hz to 10 kHz
input range
PWM selectable by jumper
Frequency
Protection Non-isolated
measurement 0.2 % from range 10 kHz
tolerance

InteliGen 200 Datasheet 3 18

 Available Extension modules
Product Description Order code
CM-4G-GPS For SMS and GPS info CM14GGPSXBX
CM-Ethernet Ethernet interface CM2ETHERXBX
CM-GPRS For SMS CM2GPRSXXBX
CM-RS232-485 Dual port interface CM223248XBX
EM-BIO8-EFCP 8 additional binary inputs/outputs EM2BIO8EXBX

Note: Maximally 2 plug-in modules can be connected in the same time.

Available CAN modules

Product Description Order code
Inteli AIN8 CAN module with 8 analog inputs I-AIN8
Inteli AIN8TC CAN module with 8 analog inputs dedicated for thermocouple sensors only. I-AIN8TC
Inteli IO8/8 CAN module with 8 binary inputs and 8 binary outputs I-IO8/8
IGL-RA15 CAN remote annunciator with 15 LEDs EM2IGLRABAA
IGS-PTM CAN module with 8 binary inputs, 8 binary outputs, 4 analog inputs and 1 analog output IGS-PTM

Note: Maximally 5 CAN modules can be connected in the same time.

Functions and protections

Support of functions and protections as defined by ANSI (American National Standards Institute):

Description ANSI code Description ANSI code

Master unit 1 Voltage unbalance 47
Stopping device 5 Incomplete sequence relay 48
Multi-function device 11 Overcurrent 50/50TD
Overspeed 12 Earth fault** 50G
Underspeed 14 Overcurrent IDMT 51
Starting-to-running transition contractor 19 AC circuit breaker 52
Synchronizing-check 25 Overvoltage 59
Thermal relay 26 Pressure switch 63
Undervoltage 27 Liquid level switch 71
Annunciator 30 Alarm relay*** 74
Overload(real power) 32P Reclosing relay 79
Reverse power 32R Overfrequaency 81O
Master sequence device 34 Underfrequency 81U
Excitation loss 40 ROCOF 81R
Unit sequence starting * 44 Auto selective control/transfer 83
Current unbalance 46

*MINT **Extension module EM-BIO8-EFCP required *** extension module IGL-RA15 required

Certifications and standards

EN 61000-6-2 EN 60068-2-6 (2÷25 Hz / ±1,6 mm; 25÷100 Hz / 4.0 g)
2
EN 61000-6-4 EN 60068-2-27 (a=500 m/s ; T=6 ms)
EN 61010-1 EN 60068-2-30:2005 25/55°C, RH 95%, 48hours
EN 60068-2-1 (-20 °C/16 h for std, -40 °C/16 EN 60529 (front panel IP65, back side IP20)
h for LT version) UL 6200
EN 60068-2-2 (70 °C/16 h)

Manufacturer:
ComAp a.s.
Czech Republic E-mail: info@comap-control.com
Phone: +420 246 012 111 Web: www.comap-control.com

© ComAp. Features and specification are subject to change without prior notice. 19
 DESIGN DETAIL

SX440 AUTOMATIC VOLTAGE

REGULATOR (AVR)
SPECIFICATION, INSTALLATION AND ADJUSTMENTS

General description Technical specification

SX440 is a half-wave phase-controlled thyristor type INPUT
Automatic Voltage Regulator (AVR) and forms part of the Voltage 190-264V ac
excitation system for a brush-less generator. Frequency 50-60 Hz nominal
Phase 1
Wire 2
In addition to regulating the generator voltage, the AVR OUTPUT
circuitry includes under-speed and sensing loss Voltage max 90V dc at 207V ac input
protection features. Excitation power is derived directly Current continuous 4A dc
from the generator terminals. Intermittent 6A for 10 secs
Resistance 15 ohms minimum
Positive voltage build up from residual levels is ensured REGULATION
by the use of efficient semiconductors in the power +/- 1% (see note 1)
circuitry of the AVR.
THERMAL DRIFT
0.04% per deg. C change in AVR ambient (note 2)
The AVR is linked with the main stator windings and the
exciter field windings to provide closed loop control of the TYPICAL SYSTEM RESPONSE
output voltage with load regulation of +/- 1.0%. AVR response 20ms
Filed current to 90% 80 ms
In addition to being powered from the main stator, the Machine Volts to 97% 300ms
AVR also derives a sample voltage from the output
EXTERNAL VOLTAGE ADJUSTMENT
windings for voltage control purposes. In response to this
+/-10% with 1 k ohm 1 watt trimmer (see note 3)
sample voltage, the AVR controls the power fed to the
exciter field, and hence the main field, to maintain the UNDER FREQUENCY PROTECTION
machine output voltage within the specified limits, Set point 95% Hz (see note 4)
compensating for load, speed, temperature and power Slope 170% down to 30 Hz
factor of the generator.
UNIT POWER DISSIPATION
A frequency measuring circuit continually monitors the 12 watts maximum
BUILD UP VOLTAGE
generator output and provides output under-speed
4 Volts @ AVR terminals
protection of the excitation system, by reducing the output ANALOGUE INPUT
voltage proportionally with speed below a pre-settable Maximum input +/- 5V dc (see note 5)
threshold. A manual adjustment is provided for factory Sensitivity 1v for 5% Generator Volts (adjustable)
setting of the under frequency roll off point, (UFRO). This Input resistance 1k ohm
can easily be changed to 50 or 60 Hz in the field by push- QUADRATURE DROOP INPUT
on link selection. 10 ohms burden
Max. sensitivity: 0.07 A for 5% droop 0PF
Provision is made for the connection of a remote voltage Max. input: 0.33A
ENVIRONMENTAL
trimmer, allowing the user fine control of the generator's Vibration 20-100 Hz 50mm/sec
output. 100Hz – 2kHz 3.3g
o
Operating temperature -40 to +70 C
o
An analogue input is provided allowing connection to a Relative Humidity 0-70 C 95% (see note 6)
o
Newage Power Factor controller or other external devices Storage temperature -55 to +80 C
with compatible output. NOTES
1. With 4% engine governing.
The AVR has the facility for droop CT connection, to allow 2. After 10 minutes.
3. Applies to Mod status S onwards. Generator de-rate
parallel running with other similarly equipped generators. may apply. Check with factory.
4. Factory set, semi-sealed, jumper selectable.
5. Any device connected to the analogue input must be
fully floating (galvanically isolated from ground), with an
insulation strength of 500V ac.
6. Non condensing.

TD_SX440 AVR_03.05_03_GB

20
 DESIGN DETAIL

Voltage
Sensing
Generator

Droop Potential
Divider &
Hand Rectifier
Trimmer Suppression

Low Hz Synchronising Low Pass

Sensing Detection Circuit Filter
Loss
Detector
Reference Power
Voltage supply

Analogue Level Power

DC Ramp Detector & Control
Input Amp
Mixer Generator Driver Devices

Exciter
Stability Field
Circuit

The main functions of the AVR are: The Stability Circuit provides adjustable negative ac
feedback to ensure good steady state and transient
Potential Divider and Rectifier takes a proportion of the performance of the control system.
generator output voltage and attenuates it. The potential
divider is adjustable by the AVR Volts potentiometer and The Low Hz Detector measures the period of each
external hand trimmer (when fitted). The output from the electrical cycle and causes the reference voltage to
droop CT is also added to this signal. An isolating be reduced approximately linearly with speed below
transformer is included allowing connection to various a presettable threshold. A Light Emitting Diode gives
winding configurations. A rectifier converts the a.c. input indication of underspeed running.
signal into d.c. for further processing.
The Synchronising circuit is used to keep the Ramp
The Sensing Loss Detector is an electronic changeover Generator and Low Hz Detector locked to the
switch, which normally connects the Amplifier (Amp) to generator waveform period.
the Voltage Sensing input and automatically changes
over to the Power input when the normal sensing voltage The Low Pass Filter prevents distorted waveforms
is lost. affecting the operation of the AVR control circiut

The DC Mixer adds the Analogue input signal the Power Control Devices vary the amount of exciter
Sensing signal. field current in response to the error signal produced
by the Amplifier.
The Amplifier (Amp) compares the sensing voltage to the
Reference Voltage and amplifies the difference (error) to Suppression components are included to prevent
provide a controlling signal for the power devices. The sub cycle voltage spikes damaging the AVR
Ramp Generator and Level Detector and Driver infinitely components and also to reduce the amount of
control the conduction period of the Power Control conducted noise on the generator terminals..
Devices and hence provides the excitation system with
the required power to maintain the generator voltage The Power Supply provides the required voltages
within specified limits. for the AVR circuitry.

TD_SX440 AVR_03.06_03_GB

21
 FITTING AND OPERATING

K1 K2 P2 P3 P4 XX X 3 2 2 1
Note. If replacing an existing SX440, position the
links and connections the same as the original
Trim A1 SX440.
K1-K2 A2
Power isolation link S1 If up grading to an SX440 refer to generator wiring
(normally fitted)
Droop diagram for connection details.
S2

1
Volts 2 Note. There are two terminals marked ‘2’
3 Sensing they are connected, either one or both can
SX440 4 links be used.
5 standard
6
7
positions
Frequency Stability 8
Selection Selection
Warning: Electrical shock can cause injury or death.
Stability Ensure that all personnel operating, servicing,
Indicator > 550kW maintaining or working near this equipment are fully
LED 50Hz 90-550kW aware of the emergency procedures in case of accidents.
UFRO 60Hz < 90kW Before removing the protective covers to carry out
service maintenance or repair, ensure that the engine is
50 C 60 CBA
inhibited and the generator is electrically isolated.

SUMMARY OF AVR CONTROLS

CONTROL FUNCTION DIRECTION

VOLTS TO ADJUST GENERATOR OUTPUT VOLTAGE CLOCKWISE INCREASES OUTPUT VOLTAGE

STABILITY TO PREVENT VOLTAGE HUNTING CLOCKWISE INCREASE THE DAMPING EFFECT
UFRO TO SET THE UFRO KNEE POINT CLOCKWISE REDUCES THE KNEE POINT
FREQUENCY
DROOP TO SET THE GENERATOR DROOP TO 5% AT 0PF CLOCKWISE INCREASES THE DROOP
VTRIM TO OPTIMISE ANALOGUE INPUT SENSITIVITY CLOCKWISE INCREASES THE GAIN OR SENSITIVITY

ADJUSTMENT OF AVR CONTROLS

VOLTAGE ADJUSTMENT CAUTION
1. Before running generator, turn the VOLTS control
The generator output voltage is set at the factory, but can fully anti-clockwise.
be altered by careful adjustment of the VOLTS control on 2. Turn remote volts trimmer (if fitted) to midway
the AVR board, or by the external hand trimmer if fitted. position.
Terminals 1 and 2 on the AVR will be fitted with a shorting 3. Turn STABILITY control to midway position.
link if no hand trimmer is required. 4. Connect a suitable voltmeter (0-300V ac) across
line to neutral of the generator.
CAUTION Do not increase the voltage above the rated 5. Start generator set, and run on no load at nominal
generator voltage. If in doubt, refer to the rating plate frequency e.g. 50-53Hz or 60-63Hz.
mounted on the generator case. 6. If the red Light Emitting Diode (LED) is illuminated,
refer to the Under Frequency Roll Off (UFRO)
CAUTION Do not ground any of the hand trimmer adjustment.
terminals as these could be above earth potential. Failure 7. Carefully turn VOLTS control clockwise until rated
to observe this could cause equipment damage. voltage is reached.
8. If instability is present at rated voltage, refer to
If a replacement AVR has been fitted or re-setting of the stability adjustment, then re-adjust voltage if
VOLTS adjustment is required, proceed as follows: necessary.
9. Voltage adjustment is now completed.

TD_SX440 AVR _03.06_03_GB

22
 FITTING AND OPERATING
STABILITY ADJUSTMENT TRIM ADJUSTMENT

The AVR includes a stability or damping circuit to provide An analogue input (A1 A2) is provided to connect to the
good steady state and transient performance of the Newage Power Factor Controller or other devices. It is
generator. designed to accept dc signals up to +/- 5 volts.

The correct setting can be found by running the generator CAUTION Any devices connected to this input must be
at no load and slowly turning the stability control anti- fully floating and galvanically isolated from ground, with
clockwise until the generator voltage starts to become an insulation capability of 500 Vac. Failure to observe
unstable. this could result in equipment damage.

The optimum or critically damped position is slightly The dc signal applied to this input adds to the AVR
clockwise from this point (i.e. where the machine volts are sensing circuit. A1 is connected to the AVR 0 volts.
stable but close to the unstable region). Positive on A2 increases excitation. Negative on A2
decreases excitation.
OPTIMUM RESPONSE SELECTION
The TRIM control allows the user to adjust the
The stability selection ‘jumper’ should be correctly linked, sensitivity of the input. With TRIM fully anti-clockwise
A-B, B-C or A-C at the bottom of the board for the frame the externally applied signal has no effect. Clockwise it
size of the generator, (see drawing). has maximum effect.

UNDER FREQUENCY ROLL OFF (UFRO) Normal setting is fully clockwise when used with a
ADJUSTMENT Newage Power Factor Controller.

The AVR incorporates an underspeed protection circuit

which gives a volts/Hz characteristic when the generator
speed falls below a presettable threshold known as the
"knee" point.

The red Light Emitting Diode (LED) gives indication that

the UFRO circuit is operating.

The UFRO adjustment is preset and sealed and only

requires the selection of 50 / 60Hz using the jumper link.

For optimum setting, the LED should illuminate as the

frequency falls just below nominal, i.e. 47Hz on a 50Hz
system or 57Hz on a 60Hz system.

DROOP ADJUSTMENT
Skill requirements of personnel
Generators intended for parallel operation are fitted with a Service and maintenance procedures should only
quadrature droop C.T. which provides a power factor be carried out by experienced, qualified,
dependent signal for the AVR. The C.T. is connected to engineers/technicians, familiar with the
S1, S2 on the AVR. procedures and the equipment.
Before any intrusive procedures are carried out,
The DROOP adjustment is normally preset in the works ensure that the engine is inhibited and the
to give 5% voltage droop at full load zero power factor. generator is electrically isolated.
Clockwise increases the amount of C.T. signal injected
into the AVR and increases the droop with lagging power
factor (cos Ø). With the control fully anti-clockwise there
is no droop.

Barnack Road • Stamford • Lincolnshire • PE9 2NB

© 2006 Cummins Generator Technologies Tel: 00 44 (0)1780 484000 • Fax: 00 44 (0)1780 484100
Limited.
TD_SX440 AVR_03.06_04_GB
Printed in England.

23