Initial Checks And Adjustments At Installation - 2301 Governor (Load Sharing Only)

Introduction

This section is a guide to be used for first installation of the engine and generator, or when a replacement of any of the equipment has been made. Too often the equipment is damaged or destroyed before it ever has a chance to be used because of incorrect wiring, lead shorts, wrong polarity or a mechanical problem.

The information that follows contains a basic, step by step checklist to be followed. Before any supply power is applied, all wiring and settings are verified to be correct. Then the governor is energized and the components are checked out to see if they function correctly. Finally the engine is started, and the complete system is checked and adjusted dynamically.

The correct use of these initial checks will eliminate most of the early failures that can occur.

Static Checks

I. Visual Inspection

II. Initial Adjustments

III. Energized Governor Checks

Dynamic Checks

I. Initial Engine Operation

II. Load Sensing Phasing

III. Phasing Procedure

IV. Load Gain Adjustment

V. De-Droop Adjustment

Static Checks

I. Visual Inspection

A. At Engine

1. Governor Linkage Checks:

a. Moves freely, not binding.

b. Correct thread engagement of rod ends.

c. Full travel available to FUEL OFF position.

d. Full travel available to FUEL ON position.

2. Magnetic Pickup to Flywheel Ring Gear Tooth Clearance, 0.56 to 0.85 mm (.022 to .033 in.). See Service Procedure K.

3. Magnetic Pickup Resistance (approximately 200 ohms).

4. EG3P & EG10P Actuator Connector:

a. Jumper must be across pins C and D of mating connector (for those actuators that use pin connectors).

5. Shielded Wire Checks:

a. Only one end to be grounded (to governor chassis).^*

b. Not in same conduit with high current cables.

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^*Except when overspeed switch is used.

B. At Governor

1. Check for shielded wire on the governor inputs that follow:

T10 & T11 (Paralleling Lines)

T14 & T15 (Ramp Switch)

T18 & T19 (Magnetic Pickup)

T20 & T21 (Jumper or Remote Speed Pot)

T22 & T23 (Engine Protection System)

T23 & T24 (SPM Synchronizer)

T26 & T27 (Droop/Isoch Mode)

2. Check for broken or loose terminals at all connections that follow:

T1 (Phase A) Potential Transformer

T2 (Phase B) Potential Transformer

T3 (Phase C) Potential Transformer

T4 & T5 (Phase A) Current Transformer

T6 & T7 (Phase B) Current Transformer

T8 & T9 (Phase C) Current Transformer

NOTE: Dynamic Checks must also be made for terminals T1 thru T9.

T10 (+) & T11 (-) Paralleling lines common to all units.

T12 (+) & T13 (-) DC Voltage Supply.

T14 & T15 Ramp Switch - Close for Rated speed or open for Low Idle speed (jumper for initial start-up).

T16 (-) & T17 (+) Actuator terminals:

a. Measure resistance (infinity) from T16 to ground and T17 to ground.

b. Remove actuator wires from T16 & T17. Measure resistance (30 to 40 ohms) across disconnected wire ends (with actuator still connected).

c. Install wires correctly back to terminals when finished.

T18 & T19 Magnetic Pickup - Measure resistance (approximately 200 ohms) in wires to and from mag. pickup (with mag. pickup connected).

T20 & T21 Speed Trim - Use 100 ohm variable resistor or jumper across terminals.

T22 & T23 Minimum Fuel - Keep open unless used for minimum fuel switch.

T23 SPM Synchronizer (common).

T24 SPM Synchronizer

T25 Connection for selection of highest battery voltage available.

T26 & T27 Open for droop, closed for isochronous operation.

T28 Connection for series or tandem actuator operation.

T29 & T30 Failsafe Circuit - Jumper terminals to activate failsafe circuit (for shutdown when there is a loss of magnetic pickup signal). Remove jumper (open) to defeat failsafe circuit.

II. Initial Adjustments (Static)

A. Rated Speed - Turn potentiometer fully CCW, then make setting at one turn back in CW direction (may require 2 or 3 turns CW if actuator does not move to FUEL ON during engine cranking). If used, set external speed trim to Mid Position (center).

B. Stability - Set to Mid Position

C. Gain - Set to Mid Position

D. Ramp Time - Set to Mid Position

E. Low Idle Speed - Set fully CW

F. Load Gain - Set fully CW

G. Droop - Set fully CCW

H. De-Droop - Factory Set

III. Energized Governor Checks (Static)

NOTE: The actuator or a 35 ohm, 10 watt load must be connected across T16 and T17.

Energize Governor

A. T12 (+) to T13 (-) - Measure voltage supply (24 to 35 VDC).

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NOTICE
40 VDC is maximum, and a voltage spike of 41 VDC will destroy the control. Use the 4W5391 Preregulator to provide overvoltage protection if a 32V battery system is used or if battery maintenance may be a problem.

B. T29 to T30 - Remove jumper, failsafe should be defeated.

C. T17 (+) to T16 (-) - Measure actuator voltage (approx. 6 VDC).

D. T29 to T30 - Install jumper for failsafe circuit operation.

E. ^*T28 (+) to T23 (-) - Measure voltage (10 ± 1 VDC).

F. ^*T17 (+) to T16 (-) - Measure voltage (0 VDC).

G. ^*T11 (+) to T13 (-) - Measure voltage (approx. 10 VDC). If voltage is found to be near 0, check to see that neither of the paralleling lines are connected to battery negative. Check all governor common points for a short to ground (T11, T15, T20, T23 & T30).

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^*If any problems are found during Tests E, F, or G, make reference to the TROUBLESHOOTING SECTION of this manual.

Dynamic Checks

I. Initial Engine Operation

A. Make sure all Static Checks are completed before Dynamic Checks are started.

B. Make sure jumper is installed across T29 and T30 for failsafe circuit operation.

C. Close the Ramp Switch (or put jumper across T14 and T15).

D. Activate 2301 Governor with power.

E. Magnetic Pickup -

1. Activate Manual Shutoff (or disconnect wires to actuator from terminals T16 & T17).

2. Crank the engine and measure output voltage of magnetic pickup across terminals T18 & T19 (should be greater than 1 VAC). ^*

3. Release Manual Shutoff (or reconnect actuator wires back to terminals T16 & T17).

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The engine can overspeed (run out of control) due to improper governor assembly or adjustment, which could result in personal injury, loss of life, and/or property damage. Be prepared to stop the engine by electrically activating the emergency air shutoff, or by manually closing the air inlets.

F. Start the engine.

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NOTICE
Be ready to control the engine shutoff manually if there is no oil pressure, or if oil pressure is too low. Damage to the engine will be the result if the engine continues to run without the correct oil pressure.

G. Rated Speed Potentiometer -

1. Set engine rated speed by turning this potentiometer CW to increase speed setting.

2. Measure Magnetic Pickup output voltage terminals at T18 and T19. Voltage should be less than 50 VAC.^*

If voltage is greater than 50 VAC, check clearance between magnetic pickup and gear tooth. Make adjustment as necessary.

H. Connect a DC voltmeter to terminals T16 (-) and T17 (+) to get an indication of actuator voltage stability.

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^*Volts AC is to be measured as a RMS voltage.

J. Gain and Stability Adjustments:

1. If engine has stability at Rated speed, slowly increase Gain (CW) until engine operation has instability (DC voltmeter needle should not be steady).

2. Now adjust Stability potentiometer slowly in either CW or CCW direction until engine has stability (DC voltmeter needle should be steady).

3. Repeat the above procedure until engine operation can no longer have full stability. Now return potentiometer to last position where engine had stability.

4. Check Gain and Stability adjustments by changing the engine speed (i.e., rapidly move the actuator terminal shaft, fuel rack lever, or use the manual shutoff for a moment).

5. If engine response is acceptable, go to Low Idle Adjustment. If it is not acceptable, do the Gain and Stability adjustments again.

K. Low Idle Adjustment:

1. Remove the jumper from T14 and T15.

2. Open the external ramp switch, if used, or remove the oil pressure switch wires from terminals T14 and T15.

3. Adjust the Low Idle Speed Potentiometer on the control to the recommended speed.

L. Ramp Time Adjustment:

1. Set the Ramp Time Potentiometer at the center position. CW rotation from this point will increase ramp time (slower acceleration rate), and CCW rotation will decrease ramp time (faster acceleration rate).

2. If external ramp switch is used, open the switch. If switch is not used, remove oil pressure switch wire from terminal T15.

3. Start the engine. The engine will now run at Low Idle.

4. With a stopwatch ready, make contact of oil pressure switch wire to terminal T15 (or close the ramp switch). Measure the amount of time it takes for the engine to get to Rated speed.

5. If more adjustment is necessary, remove wire from T15 (or open ramp switch) to bring engine speed back to Low Idle. Turn Ramp Time potentiometer a small amount in the correct direction (CW for slower acceleration, CCW for faster acceleration) and again check the new acceleration rate.

6. Do this procedure until the unit ramps at the rate desired with minimum overshoot on start.

M. Input Voltage Check (High Voltage) -

Measure the AC voltage across terminals shown:

T1 to T2 (90 to 120 VAC) or (210 to 240 VAC)

T2 to T3 (90 to 120 VAC) or (210 to 240 VAC)

T1 to T3 (90 to 120 VAC) or (210 to 240 VAC)

If these three voltages are not the same, make reference to Wiring Diagram in Service Procedure B for the correct Potential Transformer n connections.

II. Load Sensing Phasing (Dynamic Check) (Current Transformer Phasing Check)

A. Preparation

1. Connect DC voltmeter to load signal test jacks on face of control.

2. Start the engine and fully load the generator set with a unity power factor load.

NOTE: Full load is not required, if complete load is not available. However, a steady load level is necessary. As the generator set is loaded, the voltage at the load signal test jacks will increase. When the available load is reached, make a reading of the voltmeter (load signal voltage). This voltage is proportional to percent of full load (i.e., if 50% load is 3VDC, then 100% load will be 6VDC). See Section IV, page 27, for this proportional adjustment.

B. Tests

C. Results of Tests

Load signal (VDC) should decrease by 1/3 on tests for Phases A, B and C in comparison with original load signal.

1. If signal voltage decreases by 1/3, phasing is correct. Go to Load Gain Adjustment.

2. If signal voltage does not decrease by 1/3, phasing is not correct. Go to Phasing Procedure.

III. Phasing Procedure (Dynamic Check)

A. Preparation

1. Load the unit.

2. Turn Load Gain Potentiometer to the center position.

3. With DC voltmeter still connected to load signal test jacks on face of panel, do the tests that follow and put readings in PHASING TEST CHART.

4. With AC voltmeter across terminals shown in the chart, do the same tests and put the CT input voltage readings in the PHASING TEST CHART.

B. Tests

1. Phase A - Short Phase B (jumper T6 to T7) and Phase C (jumper T8 to T9).

2. Phase B - Short Phase A (jumper T4 to T5) and Phase C (jumper T8 to T9).

3. Phase C - Short Phase A (jumper T4 to T5) and Phase B (jumper T6 to T7).

C. Results for Phase A, B or C from Phasing Test Chart:

1. Calculate (find) the ratio of voltages DC/AC for each phase and put results in DIAGNOSTIC CHART.

2. Diagnosis can now be made for each phase from information in DIAGNOSTIC CHART.

NOTE: For complete information, see Phasing Procedure in Service Procedure P.

IV. Load Gain Adjustment (Dynamic Check)

1. Connect a DC voltmeter to load signal jacks (at face of control).

2. Operate engine as single unit at Full Load.

3. Make adjustment to Load Gain Potentiometer for approximately 6 VDC with engine at Full Load.

NOTE: All other units in the system must now be set to this same voltage.

V. De-Droop Adjustment (Dynamic Check)

NOTE: Do not make this adjustment unless factory setting has been changed.

1. Set the system for isochronous operation at High Idle speed.

2. Operate as a single unit, and then load the unit to 100% (engine speed will decrease).

3. Make adjustment to De-Droop Potentiometer so that the unit will return to High Idle speed.

Initial Checks And Adjustments At Installation - 2301 Governor (Standby Unit)

Introduction

This section is a guide to be used for first installation of the engine and generator (or other application), or when a replacement of any of the equipment has been made. Too often the equipment is damaged or destroyed before it ever has a chance to be used because of incorrect wiring, lead shorts, wrong polarity or a mechanical problem.

The information that follows contains a basic, step by step checklist to be followed. Before any supply power is applied, all wiring and settings are verified to be correct. Then the governor is energized and the components are checked out to see if they function correctly. Finally the engine is started, and the complete system is checked and adjusted dynamically.

The correct use of these initial checks will eliminate most of the early failures that can occur.

Static Checks

I. Visual Inspection

II. Initial Adjustments

III. Energized Governor Checks

Dynamic Checks

I. Initial Engine Operation

II. Ramp Time Control

III. Droop Operation

IV. External Speed Trim

Static Checks

I. Visual Inspection

A. At Engine:

1. Governor Linkage Checks:

a. Moves freely, not binding.

b. Correct thread engagement of rod ends.

c. Full travel available to FUEL OFF position.

d. Full travel available to FUEL ON position.

2. Magnetic Pickup to Flywheel Ring Gear Tooth Clearance, 0.56 to 0.85 mm (.022 to .033 in.). See Service Procedure K.

3. Magnetic Pickup Resistance (approximately 200 ohms).

4. EG3P & EG10P Actuator Connector:

a. Jumper must be across pins C and D of mating connector (for those actuators that use pin connectors).

5. Shielded Wire Checks:

a. Only one end to be grounded (to governor chassis).^*

b. Not in same conduit with high current cables.

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^*Except when overspeed switch is used.

B. At Governor:

1. Check for shielded wire on the governor input terminals that follow:

T7 & T8 (Magnetic Pickup)

T9 & T10 (Ramp Switch)

T11 & T12 (Remote Speed Potentiometer)

T13, T14 & T15 (Droop Potentiometer)

2. Check for broken or loose terminals at all connections that follow:

T1 (-) & T2 (+) DC Voltage Supply

T3 & T4 Failsafe Circuit:

T5 (-) & T6 (+) Actuator terminals - Disconnect wires from terminals T5 & T6. Measure resistance (30 to 40 ohms) across disconnected wires (with actuator still connected). Install wires correctly back to terminals when finished.

T7 & T8 Magnetic Pickup - Disconnect wires from terminals T7 & T8. Measure resistance (approximately 200 ohms) across disconnected wires (with the Magnetic Pickup still connected).

T9 & T10 Ramp Switch - Close for Rated Speed and open for Low Idle Speed. Jumper (close) for initial start-up.

T11 & T12 Speed Trim - For initial start-up, remove Speed Trim Potentiometer wires and install jumper across terminals T11 and T12.

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NOTICE
Do not install jumper across terminals T11 & T12 with engine running, or engine overspeed can result.

If Speed Trim Potentiometer is not used, check to see that jumper is across terminals T11 and T12.

T13, T14 & T15 Droop Potentiometer - Remove wires from these terminals for initial start-up.

T16 & T15 Ramp Time (Acceleration) Control - If used, leave terminals T15 and T16 open for initial start-up.

II. Initial Adjustments (Static)

A. Rated Speed - Turn potentiometer fully CCW, then make setting at one turn back in CW direction. If used, set External Speed Trim to Mid Position (center).

B. Stability - Set to Mid Position

C. Gain - Set to Mid Position

D. Ramp Time - Set to Mid Position

III. Energized Governor Checks (Static)

NOTE: The actuator or a 35 ohm, 10 watt load must be connected across terminals T5 and T6.

Energize Governor

A. 12 (+) to T1 (-) - Measure voltage supply (24 to 35 VDC).^*

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NOTICE
40 VDC is maximum, and a voltage spike of 41 VDC will destroy the control. Use the 4W5391 Preregulator to provide overvoltage protection if a 32V battery system is used or if battery maintenance may be a problem.

B. T3 to T4 - Defeat the failsafe circuit (see STATIC CHECKS, Visual Inspection at Governor, Step 2 for current method).

C. T6 (+) to T5 (-) - Measure actuator voltage (approx. 7 VDC).

D. T3 to T4 - Activate for correct failsafe circuit operation.

E. T6 (+) to T5 (-) - Measure voltage (0 VDC).

F. T6 (+) to T15 (-) - Measure voltage (8.5 ± 1 VDC).

NOTE: If any problems are found during these tests, make reference to the TROUBLESHOOTING SECTION of this manual.

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^*In some shutoff systems, the supply voltage is interrupted by a shutdown relay. It may be necessary to jumper around this relay.

Dynamic Checks

I. Initial Engine Operation

A. Make sure all Static Checks are completed before Dynamic Checks are started.

B. Make sure failsafe circuit is activated at terminals T3 and T4.

C. Close the Ramp Switch (or put jumper across terminals T9 and T10).

D. Activate 2301 Governor with power.

E. Magnetic Pickup

1. Activate Manual Shutoff (or disconnect wires to actuator from terminals T5 & T6).

2. Crank the engine and measure output voltage of magnetic pickup across terminals T7 & T8 (should be greater than 1 VAC). ^*

3. Release Manual Shutoff (or reconnect actuator wires back to terminals T5 & T6).

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The engine can overspeed (run out of control) due to improper governor assembly or adjustment, which could result in personal injury, loss of life, and/or property damage. Be prepared to stop the engine by electrically activating the emergency air shutoff, or by manually closing the air inlets.

F. Start the engine.

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NOTICE
Be ready to control the engine shutoff manually if there is no oil pressure, or if oil pressure is too low. Damage to the engine will be the result if the engine continues to run without the correct oil pressure.

G. Rated Speed Potentiometer

1. Set engine Rated speed by turning this potentiometer CW to increase speed setting.

2. Measure Magnetic Pickup output voltage terminals at T7 and T8. Voltage should be less than 50 VAC.^*

If voltage is greater than 50 VAC, check clearance between magnetic pickup and gear tooth. Make adjustment as necessary.

H. Connect a DC voltmeter to terminals T5 (-) and T6 (+) to get an indication of actuator voltage stability.

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^*Volts AC is to be measured as a RMS voltage.

J. Gain and Stability Adjustments:

1. If engine has stability at Rated speed, slowly increase Gain (CW) until engine operation has instability (DC voltmeter needle should not be steady.

2. Now adjust Stability Potentiometer slowly in either CW or CCW direction until engine has stability (DC voltmeter needle should be steady).

3. Repeat the above procedure until engine operation can no longer have full stability. Now return Gain Potentiometer to last position where engine had stability.

4. Check Gain and Stability adjustments by changing the engine speed (i.e., rapidly move the actuator terminal shaft, fuel rack lever, or use the manual shutoff for a moment).

5. If engine response is acceptable, go to Low Idle Adjustment. If it is not acceptable, do the Gain and Stability adjustments again.

K. Low Idle Adjustment:

1. Remove the jumper from terminals T9 and T10.

2. Open the External Ramp Switch, if used, or remove the oil pressure switch wires from terminals T9 and T10.

3. Adjust the Low Idle Speed Potentiometer on the control to the recommended speed.

II. Ramp Time (Acceleration) Control

1. If a slower acceleration rate is required, a capacitor can be added across terminals T15 and T16. For each 50 mfd of capacitance added, the acceleration rate will take two seconds longer. The maximum size of capacitor recommended is 200 mfd.

2. If capacitor is not used, leave terminals T16 and T15 open.

III. Droop Operation

1. If Droop is desired, install a 20K ohm Droop Potentiometer across terminals T13, T14 and T15.

2. If Droop Potentiometer is not used, leave these terminals open.

IV. External Speed Trim

1. If Speed Trim is desired, install a Speed Trim Potentiometer across terminals T11 and T12. A 100 ohm potentiometer is recommended, but a potentiometer with 2K ohms maximum can be used. Speed will change approximately 1% for each 20 ohms used.

2. If Speed Trim Potentiometer is not used, a jumper must be installed across terminals T11 and T12.