Kutai EG4015 数码发电机调速器用户手册说明书-USB迷|专注于互联网分享

2024年7月30日发(作者：王天骄)

EG4015

Digital Generator Governor Controller

User Manual

Digital Governor for use in Gas and Diesel Generators with smoke and IDLE controls.

Senses generator frequency, no magnetic pickup unit (MPU) is required.

Applicable to all types of generator engines and also supports External, Internal, and

PT Pump mounted actuators.

KUTAI ELECTRONICS INDUSTRY CO., LTD.

TEL : +886-7-8121771

FAX : +886-7-8121775

Website :

Headquarters : No.3, Ln. 201, Qianfu St., Qianzhen Dist., Kaohsiung City 80664, Taiwan

SECTION 1 : SUMMARY

The EG4015 uses the generator frequency to control

engine speed. It works without a magnetic pickup

(MPU), a digital circuit detects the reference frequency

from the generators output. Digital governors are not

influenced by frequency drift caused by temperature.

For example over a temperature range from -40 to +80

˚C the frequency drift is only +/- 0.1 Hz.

EG4015 uses advanced PID algorithms, together with

GAIN and DIF pots to simplify adjustments and

governor response. The EG4015 can be used in all

types of engine actuators that work with less than

15Amps and Cummins PT PUMP. LED indicators allow

users to easily determine operational and fault

conditions making it easy to install and calibrate.

SECTION 2 : SPECIFICATION

Sensing Input (S1, S2)

Voltage 1  600 Vac

Frequency 5  100 Hz

Operating Voltage (DC+, DC-)

Voltage 10  32 Vdc

Reverse Voltage Protection

Max. -50 Vdc

Actuator Output (ACT+, ACT-)

Current Continuous 9A, Max 15A for 10 seconds

Steady State Speed Band

+/- 0.25 % (with stable load)

IDLE Speed Frequency

25 Hz @ 50 Hz mode

30 Hz @ 60 Hz mode

Temperature Drift Frequency Range

0.1 Hz @ -40 to +80 ˚C

External Frequency Control (VR1, VR2, VR3)

Frequency adjustment range

+/- 2 Hz 5K ohms 1watt potentiometer

EMI Suppression

Internal electromagnetic interference filtering

and common mode ferrite beads

Static Power Dissipation

Min. 120 mA @ 12 Vdc

Min. 60 mA @ 24 Vdc

Protection Functions

Loss Sensing Protection

Actuator Short Circuit Protection activate to stop the output

Overspeed Protection activate to stop the output

Max. 57 Hz @ 50 Hz system

Max. 67 Hz @ 60 Hz system

VR Adjustment

SPEED 50 Hz : 45 to 55 Hz

60 Hz : 55 to 65 Hz

DIF PID Differential adjustment

GAIN PID Actuator output gain adjustment

DIP Switch

SW1 Actuator type OFF : External or Internal mount

ON : PT PUMP mount

SW2 Ramp time OFF : 10 seconds ramp time

ON : Immediate

SW3 frequency selection OFF : 60 Hz

ON : 50 Hz

Environment

Operating Temperature -40 to +80 ˚C

Storage Temperature -40 to +85 ˚C

Relative Humidity Max. 95%

Vibration 5 Gs @ 60 Hz

Dimensions

162.0 (L) x 112.0 (W) x 43.0 (H) mm

Weight

330 g +/- 2%

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2 EG4015

SECTION 3 : APPEARANCE / DIMENSIONS / INSTALLATION DRAWING

112.0

88.0

Accessory package

Four ea. M5L30 bolts

5.2

18.3

138.0

162.0

43.0

29.5

Unit : mm

Figure 1 Outline Drawing

SECTION 4 : ALARMS AND WIRING DIAGRAM

ATTENTION

1. Installation personnel must receive training. Defective installations may cause damage and injury to

personnel.

2. Always install an independent shutdown device. If by chance power is lost the generator can stop and

avoiding damage to equipment and personnel.

3. Install a second engine shutdown device is suggested, such as an emergency fuel switches or air

intake damper in order to immediate stop the engine if there is a system failure.

4. Always use a 20A slow-blow fuse between the battery and the governor.

5. Use #AWG10 (2.58 mm

) or a higher between the battery and the actuator.

6. SENSING wire to (S1, S2) must be # AWG18 (1.02 mm

) with an insulation voltage rating of 600V or

higher.

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EG4015 3

GAIN adjustment

DIF. adjustment

SW2

Generator frequency

SW3

DIP

SW1

OFF

External or Internal

mount actuator

10 seconds ramp

time

60 Hz

PT PUMP mount

actuator

Immediate start

50 Hz

Flashing：Standby, not

operating

Steady：Sensing Input Active

Steady：Open detected

Steady：Actuator over

current (short circuit)

Steady：Engine overspeed

S1, S2 terminals L1, L2

(phase-to-phase) always

connect to input side of the

breaker.

20A

Fuse

L-L

Power SW

Generator

Load

12/24 VDC

Actuator

SW-A Engine Start Switch

Open：Disabled

Closed：To force actuator output

when no residual generator

SW-B Engine IDLE Switch

voltage is present on startup.

Closed：Engine @ IDLE speed

25 Hz @ 50 Hz mode

30 Hz @ 60 Hz mode

Shield Ground

Use wires with shield (Mylar foil insulation

with copper grounding wire) grounded on

one side only.

External Frequency Control

5K ohms 1 watt potentiometer：+/- 2 Hz

Leave the terminal open when no external

pot is used.

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4 EG4015

SECTION 5 : INSTALLATION

5.1 Inspections before starting engine

5.1.1 Check that all wiring is correct. Before starting

the engine, turn on the power source to the unit

(Power SW) and close the engine start switch

(SW-A). The actuator will be forced to its

maximum on position confirming that the wiring

between the battery and the actuator are working

normally. This also confirms the actuator is

working smoothly without getting stuck. Repeat

several times to check the operation.

5.1.2 Set GAIN, DIF potentiometers (pots) to a central

position.

5.1.3 If the external frequency control potentiometer is

used, it should be adjusted to its central position.

Keep these terminals open when not in use.

5.1.4 DIP SW 1, 2, 3 should be set to the desired

modes of the system.

5.1.5 Idle setting. With SW-B closed the engine will

enter IDLE speed (25 Hz or 30 Hz). When SW-B

is opened the engine will go directly to the rated

speed (50 Hz or 60 Hz). Select according to

generator requirement.

5.1.6 Use an analog frequency meter while making

adjustments to make it easier to measure

changes in generator frequency.

5.1.7 We recommend installing a fuel switch that can

immediately shutdown the engine when the

system is not operating normally.

5.2 Starting the engine

5.2.1 After turning on the unit power (Power SW) start

the engine.

5.2.2 When the starter motor begins to turn terminals

S1, S2 will detect the starting frequency and the

actuator will be forced to its maximum engine

start output (pulled to all the way on). After the

engine is started (frequency > 18 Hz), the

controller will automatically adjust the actuator

according to frequency.

5.2.3 If the residual voltage of the generator is too low

( < 1 Vac @ 5 Hz) terminals S1, S2 cannot detect

the starting frequency and the actuator will have

no output, thus preventing the engine from

starting. In this situation connect the engine start

switch (SW-A) directly to the starter motor.

Alternatively, when the engine is starting close

EG4015

the engine start switch (SW-A). The actuator will

open to full output when the engine is cranking

helping the engine to start smoothly.

5.3 IDLE (IDLE) operation

Engine is started and SW-B is closed : the engine

will enter IDLE speed (25 Hz or 30 Hz). When the

engine IDLE Speed countdown is completed SW-B will

open and the engine will reach the rated frequency (50

Hz or 60 Hz).

Engine is started and SW-B is opened : engine will

go directly to the rated operating frequency.

5.4 Engine Speed Ramp Time

5.4.1 DIP SW2 OFF - the ramp up time from IDLE

frequency to rated frequency is 10 seconds.

5.4.2 DIP SW2 ON - the generator will immediately go

to rated frequency.

5.5 Unstable engine speed

If the engine speed is unstable when running adjust the

GAIN pot counter-clockwise (CCW) until the engine

stabilizes.

5.6 Generator frequency adjustment

When the engine speed is stable, then adjust the

SPEED potentiometer on the governor or the external

5K frequency pot to your rated frequency (50 or 60 Hz).

5.7 Restart the generator

Shutdown the generator and restart to confirm that the

governor is controlling engine speed and starts

smoothly. If it is stable during this period then go to <

SECTION 6. Optimal Engine Response Adjustment

Procedure > below  but if not stable repeat Step 5.1.

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SECTION 6 : OPTIMAL ENGINE RESPONSE ADJUSTMENT PROCEDURE

6.1 After Step 5. Installation is completed and engine start operation is smooth, carry out the following

adjustments with generator in a no-load condition.

6.2 Slowly adjust the GAIN potentiometer clockwise (CW) until frequency swings rapidly, then slowly adjust in a

counter-clockwise direction (CCW) until the frequency is stable. Wait for the frequency to stabilize, then

adjust a further turn counter-clockwise (CCW).

Adj Slowly

FREQ

Adj Slowly

CCW

FREQ

CCW 1/2 Grid

GAIN

TIME

GAIN

TIME

GAIN

6.3 Slowly adjust the DIF pot (CCW) until the frequency goes from stable to oscillating, then slowly adjust (CW).

The oscillations will gradually stabilize. Wait for the frequency to stabilize then turn (CW) approximately one

more time.

Adj Slowly

FREQ

CCW

Adj Slowly

FREQ

CW 1 Grid

DIF

TIME

DIF

TIME

DIF

6.4 Push (or tap) the arm of the actuator with your hand or add a load to the generator and observe how the

frequency recovers. If normal it should return quickly to stability. If further adjustments are required then

repeat Steps 6.2 and 6.3 to readjust.

6.5 Optimal response curve and the DIF potentiometer adjustment.

DIF setting insufficient - oscillations DIF setting for optimal response DIF setting too high. Frequency

continue long after a load has added curve recovers too slow after a load has

been added

FREQFREQFREQ

LOAD

TIME

LOAD

TIME

LOAD

TIME

6.6 Optimal response curve and the GAIN adjustment

GAIN setting too low. Frequency GAIN setting for optimal response GAIN setting too high.

recovers slowly after a load is added curve

Oscillations continue far too long

after a load is added

FREQFREQFREQ

LOAD

TIME

LOAD

TIME

LOAD

TIME

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6 EG4015

SECTION 7 : TROUBLESHOOTING

PROBLEM

7.1 Engine Overspeed

CORRECTIVE ACTION

1. Engine overspeed caused by inappropriate setting of GAIN & DIF

potentiometers. Adjust settings according to procedure in Step. 5.

2. Check whether or the wiring for the voltage detection inputs (S1, S2) is normal,

and whether or not the residual voltage produced is > 1 Vac.

3. Check whether actuator is stuck in lowest position, causing overspeed.

4. If all of the checks above are normal then change the EG4015 controller.

7.2 Actuator cannot open 1. Check if the battery voltage is below 10 Vdc.

completely to maximum

2. Check if the actuator has overheated.

output

3. Check whether the actuator specs. match the driving power supply voltage.

4. Check that the linkage between the actuator and the fuel valve is not impeded.

5. For actuator installation refer to “Electronic Governor Controller Concept”

/en/

7.3 Actuator

operate

does not 1. Check the power switch and the fuse.

2. Using an ohm meter measure ACT+, ACT- terminals will measure the internal

resistance of the actuator (pay attention to measurement polarity). If the

actuator is damaged it is possible that the measured resistance level will not

meet the specifications of the actuator. Change the actuator to meet system

requirements.

3. Confirm that the actuator has been installed in accordance with Step 5.1.1

7.4 Over Current (short 1. Check whether or not the actuator is short-circuited.

circuit) protection lamp

2. Check whether the actuator has a parallel diode. Ensure that the ACT+ is

illuminated

connected to the N (Cathode) pole of the diode, and ACT- is connected to the

P (Anode) pole.

7.5 Engine will not start 1. If it cannot be opened to the maximum then reference Step 7.2 above.

2. Check whether there is sufficient fuel and the fuel switch is open.

3. It is possible that air could be trapped in the fuel line.

4. Check the fuel time for leaks. Try manually operating the engine.

7.6 Engine speed oscillates 1. Measure voltage between B+ and B- on the EG4015. If voltage is insufficient

irregularly ( < 10 Vdc) it could possibly cause irregular operation. Change the battery.

2. RFI caused by improper shielding. Fix shield grounding wire.

7.7 Engine speed continually 1. Gain adjustment is not good. Re-adjust Gain setting according to Step

swings after a load is SECTION 6. Optimal Engine Response Adjustment Procedure.

added

7.8 Frequency oscillates in a 1. Check the linkage between the actuator and the fuel valve, either too tight or if

small range there is a gap (too loose). Correct any problems with the linkage.

7.9 Radio Frequency 1. Install EG4015 in a grounded metal case in order to shield from RFI.

Interference (RFI)

causing irregular engine

speed oscillations

※

Appearance and specifications of products are subject to change for improvement without prior notice.

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EG4015 7