01 Operation Manual For Speed Controller

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 WORKS1 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-EBall 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-E1-1-5 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-Eo 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-EChapter 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-E1-2 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-E1-3 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-E2. 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 Maco ore) Hsia SAOPASE gy A i seas) ‘ovo SEISAKUSHO ¢0.,L7D Waa a Fe | fe 0428-32-8551 5 ®@ ®@ ‘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 10Q) 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 14the 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 16Chapter 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-ELW 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-EProblems: 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 19Chapter 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 202-2 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

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