OPERATION MANUAL
for
Speed Controller (Electronic Governor)
<
>
(XS-400B-03)
Part No. 04410-33100
@ Revision history
Revision date_| Operation manual No. Reason for revision
1994.12.15 NN80004A-J First edition issued
1996.02.05 NN80004B-J Form amended
1996.10.01 NN80004B-E _English editionissued__|
MITSUBISHI HEAVY INDUSTRIES, LTD.
SAGAMIHARA MACHINERY WORKS 1
A. Speed controller
04410-33100 (XS-400B-03)
Index
Chapter 1 Preparations.
1. Installation...
1-1 Installing the actuator...
-1 Mounting plat
-2 Setting the actuator operating range
-3 Actuator lever and 10d snsnsssensen
-4 Linkage
1-1-5 Hames connections
2, External dimensions...
3. Wiring connectioris
3-1 Precautions in performing wiring connections..
38-2 Witing connections
Chapter 2. Operation..
1. Operating principles.
1-1 Fundamental operation .. :
1-2 Operating principles and functions (block diagram)
1-3 Operating principle
2. Operation procedures.
2-1 Precautions in operation .....
2-2 Control operation name and functional descriptions...
2.8 Setting method ..
2-3-1 Necessities for adjustment..........
2-3-2 Setting position.
Chapter 3. Troubleshooting.
1. Corrective action ..
1-1 Control flow and trouble...
Chapter 4 Specifications
1. Specifications...
2. External input and rack set...
2-4 External input..
2-4-4 General description.
2-2 RACK SO eesensnst
2-21 General description. Chapter 1 Preparations
1. Installation
1-1 Installing the actuator
1-1-1 Mounting plate
Install the actuator to be at right angles to the ground line. In addition, design a frame
(board thickness at least 6 mm) strong enough to be free from resonance, and in some
cases use such as a vibrationproof rubber to protect against vibration,
1-1-2 Setting the actuator operating range
(a) Fully closed side
‘Check to ensure that the actuator lever is at its fully closed position, then connect the
lever with the rod on the engine side, and adjust to a position at which the engine stops.
‘The actuator, if installed rather open, will function as a mechanical stopper, reducing
the life of the actuator.
(b) Fully opened side
Full rack in the operation status will be adjusted. If RPM is reduced in the vicinity of
the rated load when operation at the load is performed, the actuator may have been
fully opened. In the same manner as the fully closed side, if the actuator functions as
an external stopper before being fully opened, it will reduce the life of the actuator.
Warnings:
The actuator is a mechanical part. Be sure to perform the actuator unit inspection
individually including rod and linkage, hamess connections, ball-joint parts, in
daily servicing and regular inspection.
1-1-3. Actuator lever and rod
As shown in Fig. 1, insert flat washers between the lever and the rod end, and the rod
end and the bolt of the actuator to reduce friction in these areas. Insert the lever
properly as far as the root of the actuator output shaft, and firmly tighten the
accompanying hexagon socket head cap screws (about 100 kef-cm) to provide screw
locking. In addition, grease the rod end regularly.
NNG0004B-E Ball joint
Flat washer
Fig.1 Lever and rod end
1-1-4 Linkage
As shown in Fig. 2, ensure that the rod and the actuator lever is installed in the angle @
of 170° or so when engine stops (Controller GAIN can be increased.)
Injection pump
SOS Mouser rer
Fully closed Fall opened
| Hh Actuator
Fig.2 Linkage
NN80004B-E 1-1-5 Harness connections
Link the hamess connector properly (o the actuator receptacle to ensure that the hamess
will not fall off.
Cautions:
(1) The connector is not waterproof, Care should be taken to ensure that the
connector will not be exposed directly to moisture when it is steam-cleaned.
In addition, perform waterproofing.
(2) Periodically inspect the connection of the hamess connector and actuator
receptacle.
2, External dimensions
— 59 —>y
Toro stisuste 9.07
Whee ale
te odd 2
be. 95, 4-96 hole
Fig. 3 Outline diagram
NN800048-E o
3. Wiring connections
3-1 Precautions in performing wiring connections
Warnings:
MM Wiring connections should be performed by personnel who have been trained in
fundamental: electrical, mechanical engineering and have practical business
experience,
@ Tum off the power supply before performing wiring connections.
(1) Usea shielded cable as input signal conductor. Do not peel the sheath of the
shielded cable more than necessary for wiring connections,
(2) Ensure that the input signal conductor is wired at intervals as far as possible
from the power-supply cables for meter, motive power and load in order to
avoid being affected by noise induction.
3-2 Wiring connections
Warnings:
1 Upon completion of all wiring connections, recheck for any miswiring before
turing on the power supply.
St 6 netic
8
External input 1
Extemal input 2
A
Actor x
1
2
External input3 | 3
4
5
Fig.4 Connection diagram
NN60004B-E (1) When the rack-set function is not used, be sure to jump-cut between terminals 9
and 10. When used, have ready a 10 KQ potentiometer to connect between
terminals 8 and 10, and connect the brush to terminal 9,
(2) When the idling-set function is used, have a 10kQ potentiometer to connect
between terminals 8 and 11, and connect the brush to terminal 1. And then have to
install the change ovér switch between the brush to terminal 1.
NNE0004B-E Chapter 2 Operation
1, Operating principles
1-1 Fundamental operation
Speed
Engine output shatt } >| controller +| oul:
ting gear
Engine's running speed
detector
(Magnetic pickup)
Fuel injection pump |
‘Actuator output lever
Fig.5 Principle diagram
(1) The ring gear passes through the tip of the magnetic pickup mounted on the
flywheel housing, by which a signal proportional to the engine's running speed is
sent to the controller.
@) This signal is proportioned, integrated, differentiated, and amplified by the
controller, and sent to the actuator,
(3) The actuator converts the electric signal from the controller into a mechanical
output, precisely controlling the engine's running speed.
NN80004B-E 1-2 Operating principles and functions (block diagram)
<3>
<8>
<7>
<9>
<18>
<15>
<17>
<19>
Rack set
External input, 2
RPM setting
(variable resistor)
Deviation amplification and
GAIN adjustment
Proportion, P
Droop
Control
Current detection
Frequency-voltage
converter’
Fuel injection pump
<2>
<6>
<8>
<10>
<12>
<16>
<18>
<20>
External input, 4
External input, 8
Comparator
Differentiation, D
Integration, |
Limit
Power control
Actuator
Magnetic pickup/Speed
detector
Eng
Fig. 6 Controller block diagram
NN80004B-E 1-3 Operating principles (see Fig. 6)
(1) Rotating speed (RPM) detection
The signal representing the engine RPM originates at the tip of a magnetic pickup
located close to the engine's flywheel housing ring gear. The ring gear teeth moving
past the tip of magnetic pickup induce an alternating signal, whose frequency is
proportional to the rotating speed(RPM) of the engine,
(2) Frequency-voltage converter
Converts the above AC signal into DC voltage.
(3) RPM setting
The value of RPM, to which the running engine is to be brought by control, is
established and set as DC voltage. It represents the target speed for the controller.
(4) External RPM settings 1, 2 and 3
By applying extemal DC potentials to the RPM settings of Step(3) above, the engine's
RPM can be varied,
(5) Deviation amplification, GAIN adjustment
Comparing the DC voltage of the set RPM with the DC voltage proportional to the
engine's running speed, a deviation signal proportional to the difference in the engine's
running speed is amplified and output.
© P for proportion
AA signal is output that is proportional to the above deviation signal.
(7) [for integration
A signal is output that is proportional to the integrated valve, relative to the deviation
change by time, in response to the above deviation signal,
(8) D for differentiation
A signal is output that is relative to the deviation change ratio, in response to the above
deviation signal.
NN800048-E (9) Power control
This power control calculates the signals detected in Steps (6) to (8), and then changes
them through pulse width modulation (PWM) into the power required for actuator's
operation.
(10) Auxiliary functions
a. Droop
By feeding back the power needed for control operation, the engine is enabled to
change its running state (load-and-speed relationship) on and along the given droop
line, a characteristic curve, in addition to isochronous operation.
b. RPM input detection
In operation, if the RPM signal from the engine RPM detection (magnetic pickup)
becomes absent ( or decreased to 10 Hz downward), the power control input is
shut off, and the actuator output shaft is moved in the direction of stopping fuel
supply (and tumed to the safety side).
ce. Limit
‘When the deviation signal is excessively large while the actuator is moving in the
direction of increasing fuel supply, the limit circuit will restict the output signal.
a. Rack set
This function is the electrical limiting of the maximum opening of the actuator and
is accomplished by limiting the signal in the control power control section,
NN60004B-E 2. Operation procedures
2-1 Precautions in operation
Warnings:
M Operation should be performed by personnel who have been trained in
fandamental electrical and mechanical engineering and have practical business
experience.
2-2 Control operation name and functional descriptions
SPEED CONTROLLER
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‘ovo SEISAKUSHO ¢0.,L7D
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fe 0428-32-8551 5
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‘4% PP
2-2-1 Adjusting the trimmer
(1) DR trimmer (droop adjusting trimmer)
Adjustment is done when droop operation is required.
Input and cut off the load in the sequence of 0%, 100%, 0%, and 100%, and select to
adjust the droop ratio from the difference in the engine's running speeds at 0% and
100% load. Turning clockwise this trimmer will increase the droop ratio.
NN800048-E
10 Q) GAIN trimmer (deviation amplification output GAIN adjusting trimmer)
Sensitivity of proportional control signal is increased by this timmer because
deviation between the engine RPM and the set RPM is amplified.
Turning clockwise will increase its amplification.
(3) Timmer (integration adjusting trimmer)
When a difference is caused between the set RPM and the actual engine RPM, the
controller reaction speed is adjusted by this trimmer,
‘Turning clockwise will acclerate the reaction time.
(A) D trimmer (differentiation adjusting trimmer)
When a difference is caused between the set RPM and the actual engine RPM,
judgment of this difference is given presupposedly.
‘Tuming clockwise will increase the presupposition time.
(5) SP trimmer (RPM setting trimmer)
This trimmer, unlike others, uses a multiple revolution trimmer (18 turns), Turning
clockwise will increase the set RPM.
2-2-2 Pilot lamp
© OP lamp (operate red light-emitting diode)
Itis lit when the power supply is applied to the controller and the input signal from the
magnetic pickup is at least 10 Hz. The controller does not work unless this pilot lamp
is lit,
2-3 Setting method
Necessities for adjustment
1, Small flathead screwdriver (tip: width x thickness Smm x 0.6mm )
IL DC ammeter (such as tester)
2.3.2 Setting position
(1) Initial setting position of each trimmer
Initial setting position of each timmer is as follows: If different, set at the i
NN80004B-E
” setting position.
Trimmer | OR | GAIN f D SP
Position | 0% | 20% | 60% | 50% | About 6oOrpm, but with 182 rng gear
teeth
Note 1: Percent in the table indicates the position of each trimmer in %, each division
of the trimmer showing 10%.
Note 2: DR trimmer is 0%, which provides isochronous operation.
(2) Recheck the wiring connections. Give particular attention around the power supply.
Warnings:
1 Upon completion of all wiring connections, recheck for any miswiring before
turning ’on the power supply. Please be aware that reverse wiring of the power
cables for terminals S+ and S-, in particular, will damage the controller.
(3) Before starting the engine, ensure that the engine can be emergency-stopped at any
time as an action to take against abnormality,
Warnings:
Assign an operator to ensure that the engine can be stopped by overspeed relay and
that the emergency stop button can be pressed any time, Turn off the power supply
and close the actuator fully to cut off the fuel supply.
@ Applying the power supply
Prior to starting the engine, apply the power supply to the controller, and use a DC
ammeter (such as tester) to check the voltage between terminals 8 and 10. Unless the
reading is some 8 VDC or so, the controller may be improper.
Measure the voltage between
terminals 8 and 10,
NN80004B-E
12 (5) Starting the engine
Except when the engine has overshooted more than the rated RPM, slowly tum the SP
timmer clockwise, and set practically to the rated RPM (or rated generating
frequency).
SP trimmer
Cautions:
When the engine greatly hunts or cannot be started, refer to the troubleshooting for
solutions.
(© Controller limit adjustment procedures (rough adjustment)
1) GAIN trimmer
Slowly turn the immer clockwise, and when the engine starts hunting, slowly
turn counterclockwise to set the trimmer ata position where hunting stops. When
the engine does not hunt if tumed full clockwise, move the actuator lever by hand
to induce hunting.
‘This action meaning is the making chance of hunting for latent govemnor hunting.
NN80004B-E
13 ¢
1
2
GAIN trimmer
Cautions:
MM When moving the actuator lever by hand, care should be taken to ensure that the
hand will not be pinched,
2) D trimmer
Acdjust the trimmer in the same manner as the GAIN trimmer.
3) SP trimmer
Adjusting the GAIN and D trimmers will change the RPM setting. Set again to the
rated RPM with the SP trimmer.
(7) Checking the operation at the load
Slowly apply the engine load until reaching the rated load (110% of the rated load as
NN80004B-E
14 the case may be), and check to see that hunting is absent, and that the rated load
operation can be effected.
When the rated load operation cannot be effected, readjust the link to control the fuel
supply quantity.
(8) Governor performance adjustment (fine adjustment) and procedures
Input and cut off a load of about 25% the rated load, and measure the governor
performance with a frequency meter or electromagnetic oscillogram. Looking at the
results, go on with the adjustment. If no problem is seen, increase the load in 25%
increment repeatedly, and check.
© Improving the maximum frequency variation
I. Tum clockwise the GAIN trimmer in increment of about 5 degrees to input
and cut off the load repeatedly until the engine hunts.
TI Turn clockwise the D timmer in increment of half the division or so, and
input and cut off the load repeatedly until the engine hunts. If hunting is
absent, OK with tuming full clockwise,
© Improving the recovery time
1 Turn clockwise the I trimmer in one division 10% increment or so to input
and cut off the load repeatedly,
GAIN trimmer Dimmer
Cautions:
HM Tuming the I trimmer clockwise excessively to reduce the recovery time will
increase overshooting when starting the engine.
NN80004B-E
15 (9) Droop operation adjustment and procedures
I. Start the engine and provide operation at no-load,
IL Slowly turn the DR trimmer clockwise, at which time the engine RPM increases
normally. Correcting with the SP timmer to the rated RPM, set the DR trimmer at
three divisions (30%).
IIL Slowly increase the load until reaching 100% the rated Joad, check the droop ratio
from the reduced RPM, and if insufficient, further turn the DR trimmer clockwise
at no-load, repeating steps I to III, and set to a desired droop ratio.
DRtimmer
Cautions:
1M The droop of this controller uses the consumed current of the actuator as a signal,
and therefore the hysteresis of the actuator as it is appears as control value. When.
droop without hysteresis is required, use the system with feedback potentiometer
function.
NN800048-E
16 Chapter 3 Troubleshooting
1. Corrective action
Warnings:
When corrective action is taken as a result of troubleshooting, observe the following
conditions for the corrective action marked .
™@ Wiring connections should be performed by personnel who have been trained in
fundamental electrical, mechanical engineering and have practical business
experience.
ML Take corrective action after ensuring that the power supply is tumed off.
When corrective action taken in accordance with the following troubleshooting still
does not solve abnormal operation, report to our sales personnel or branch office
nearest to you.
1-1 Control flow and trouble
Apply the power supply.
No
Engine cranking with starter motor does not
start the engine.
No
Actuator does not operate at all.
No
Rated RPM cannot be set at.
No
Overspeed due to large overshooting stops
engine,
No
Engine hunts, and controller control does
not reach steady-state condition.
No
Rated load operation cannot be performed
(engine refuses to take on the load.)
No
End of setting
Yes
Yes
Yes
Yes
Yes
Yes
Refer to item A of
trouble contents.
Refer to item B of
trouble contents.
Refer to item C of
trouble contents.
Refer to item D of
trouble contents.
Refer to item E of
trouble contents.
Refer to item F of
trouble contents.
7
NN80004B-E LW
Problems
Cause
How to find
Corrective action
‘A. Engine cranking
‘with starter motor
does not start the
engine. (Every
time the engine is
cranked, actuator
lever moves to
maximum fuel
supply position.)
No fuel is supplied to
engine,
Control engine manually
for tia,
Check fuel
system.
to Check safety
devicefl,
B. Actuator does not
operate at all.
Reversely wired
terminals S+ and S-, and|
loosened terminal
screws
Check wiring,
connections of
terminals S+ and S-
Comect wiring
connections, and
replace or
additionally
tighten screws of
controller.
Power-supply voltage is
mot applied normally.
<> Disconnect wiring of
terminals Si+ff and S-
. and measure power-
supply voltage wi
DC yolimeter,
Normalize supply
voltage.
<> Use larger power
lead cables.
Broken harness wire
« Disconnect wiring
between controller
terminals 4 and 5, and
check resistance value.
Ifnormal, a resistance
value of about 3 2 is
shown, Infinity
resistance indicates
‘broken harness
Replace harness.
Linkage stickilng
‘Move by hand, and check
to see if linkage moves
smoothly.
Make the linkage
smooth,
No signal is output from
< Check that OP tamp is
‘ If voltage is less
ia icky} lit, When engine is then 1 VAC,
=e | eeeeclage| tear A
Riahahawsi between 6 and 7. replace pickup.
Defective actuator | Replace with another | Replace actuator.
actuator for trial.
Remove actuator
receptacle, and
measure resistance
value of between
receptacle terminal pin
and body of actuator.
For non-defectives,
resistance on each pin
indicates infinity
If short-circuited
or some resistance|
value is shown,
replace actuator.
18
NN800048-E Problems: Cause How to find Corrective action
B. Actuator [Defective actuator | Measure resistance value | Replace the actuator.
does not between actuator
operate at receptacle pins A and B.
all. Ifinfinity resistance is
indicated, coil in the
actuator is broken,
Defective controller | Ifno abnormality is Replace controller.
observed upon checking | 215 Replace batter
(Undercharged ep ry.
battery) all above, measure Check wiring lengths and
voltage between fiameter batter
terminals 8 and 10.1fune | ayncers between batery
reading is on the order of id 7
EvDe inten acy | controller and actuator:
abnormal if otherwise,
psi Higeeteal Distance | Gable Size
between terminals 8 and | [~0~10m | 1.25mant
rear eneek acta | | 10 20m | 3.smnt
) mature aso votige | [_20-300_| 5.5mm
between terminals S+
and S.. Ifthe reading is,
less than 16 VDC,
battery is undercharged.
C Rated | Defective trimmer or | Check that current actuator | Ifturning SP timmer
RPM printed cireuit board | opening has room on opening | clockwise does not
cannot be side, increase engine RPM,
set at. trimmer or printed ciréuit
board is defective.
D. Overspeed {I trimmer is Tum the I cimmer Reset in accordance with the
due to | excessively turned ‘counterclockwise (about | recovery time.
overshootin | clockwise. 40%), and recheck. If trimmer is to be turned
g stops clockwise, first tam GAIN
engine. trimmer clockwise to some
degree.
‘Too large SP trimmer | Tur SP trimmer 18 turns | In case of overspeed again,
setting counterclockwise, and | replace controler,
\ recheck, I speed is reduced, set by
) slowly turning SP trimmer
clockwise.
Engine | Too large GAIN Lever of actuator hunts at 2 | Slowly tum GAIN immer
hunts, and | setting value to3 Hz, counterclockwise to stop
controller hunting.
control | Too large D trimmer | Lever of actuator hunts at 4 | Slowly turn D immer
does not | setting value toS Hz, counterclockwise to stop
reach hunting,
steady-
state’
condition. | Ttrimmer is Lever of actuator vibrates | Slowly turn I trimmer
excessively turned | with small amplitude at about} counterclockwise to stop
clockwise. 1 Hz, and engine rack hunting,
position changes slowly.
F, Rated load | Insufficient fuel ‘Check actuator opening. Therease fuel supply.
operation | supply
cannot be
performed,
NN&0004B-E
19 Chapter 4 Specifications
1. Specifications
Item Contents
Type. XS-400B-03
Power-supply voltage 24v DC
Voltage allowance 410%
Consumed current (individual unit) | About 100 mA.
Consumed current (combination) | About 2 A (at steady-state condition under control)
Input Speed control input: Magnetic pickup frequency more
than 1 VAC min,
Output frequency 200Hz PWM.
Frequency setting range (main body) | SP trimmer setting range: 2000 to 6000 Hz
Allowable ambient temperature =10 10 60°C
Accuracy Within 1.0%
Service atmosphere A place free from corrosive gas
Weight About 0.8 ke.
Cautions:
MM Connectable actuator output torque is up to 30 kgf-cm.
2. External input and rack set
2-1 External input
‘This equipment can change the RPM setting extemally by using extemal input
terminals 1, 2, and 3.
2-1-1 General description
controller, which changes the RPM setting.
Standard inputis 4 VDC.
Inputting 4 VDC will set the SP trimmer of the controller.
Inputting more than 4 VDC will provide a higher RPM than that set by SP trimmer of
NN80004B-E
20 2-2
2-2-1
the controller,
Inputting less than 4 VDC will provide a Jower RPM than that set by SP trimmer of
the controller.
* Tis recognized that terminal with no input is provided with an input of 4 VDC in
the controller.
A change in voltage of 4 VDC will cause a change of about 3000 Hz equivalent to
about 980 rpm with an engine having 182 ring gear teeth,
For example, inputting 8 VDC to the controller set at 1500 rpm from terminal 1 will
provide about 2480 rpm, while inputting 0 VDC will set 520 rpm.
In addition, three input terminals are set at a value with each added up.
For example, inputting 6 VDC from terminal 1, 2 V from terminal 2, and 5 VDC
from terminal 3 to the controller set at 1500rpm will, as shown as follows:
(6-4) + (2-4) + (5-4) =1V,
increase RPM by a portion of 1 V (about 1745 rpm).
Rack set
‘This equipment can electrically control the maximum actuator opening externally by
using external input terminal 9, which is effective for prevention of black smoke when
starting the engine.
General description
Terminals 9 and 10 (8 VDC) are short-circuited at shipment, and reducing this voltage
will permit the control of the maximum actuator opening.
Use by connecting a potentiometer to controller terminals 10 (8 VDC) and 8 (0 VDC).
NN800048-E
21