Electronic Governor Troubleshooting Guide Rev a 03 2008

7/30/2019 Electronic Governor Troubleshooting Guide Rev a 03 2008

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ELECTRONIC GOVERNORSADJUSTMENTS I CALIBRATIONAND COMPONENT

TROUBLESHOOTING GUIDE

~ WESTERBEKEWESTERSEKE CORPORA170N MYLES STANDISH INDUSTRIAL PARK150 JOHN HANCOCK ROAD, TAUNTON, MA ()27lJO.?3f9 U.SA

TEL: (508)823-7677 FAX: (508)SS4.s6B8WEBSITE: MVW.WESTERBEKE.COM Revised Edition AMarch 2008


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THE ELECTRONIC GOVERNORGENERATOR MODELS UP TO JUNE 2004

DESCRIPTIONA generators engine must run at a constant speed to enablethe generator to produce the stable AC power (hertz)required.The Electronic Governor consists of three components, theCONTROWR, a pc board installed in the control panel. AMAGNETIC PICKUP (MPU) installed in the bellhousing overthe engine flywheel and the linear ACTUATOR .mounted on theengine and attached by linkage to the injection pumpthrottle control.The Electronic Governor regulates the engine speed bysensing the engine's RPM with the maguetic pick-up at theflywheel. The governor's controller continuously monitorsthe engines speed and i f here is any discrepancy, thecontroller signals the actuator and the actuator adjusts theengine to the desired speed electronically.CONTROLLER ADJUSTMENTThe controller has two adjustments: the SPEED adjustmentis used to increase or decrease the the engine's speed to thedesired hertz. The GAIN adjustment affects the reactiontime of the actuator to the generator load changes.NOTE: A high gain adjustment can induce an oscillatingof he actuator producing a hunting mode. In such cases,lessen the gain adjustment.CALIBRATION1. With no power to the governor (engine not running),adjust the GAIN potentiometer to 9:00 o'clock.2. Start the engine and adjust the speed by turning thespeed pod clockwise to desired speed.

NOTE: Controllers are factory adjusted to minimumRPM. However, for safety, one should be capable ofdisabling the engine if an overspeed should exist.3. At no load, tum the GAIN potentiometer clockwiseuntil the engine begins to hunt. I f he engine does nothunt, physically upset the actuator linkage.4. Thm theGAIN potentiometer counterclockwise untilengine runs stable.

NOTE: Controllers are available in 12 and 24 VDCmodels. The operating voltage range is + or - 20%. Ifthe voltage varies above or below this range, thecontroller will not operate and the engine will run inthe idle mode until proper DC voltage is supplied tothe controller.

ELECTRONIC GOVERNOR ADJUSTMENTSThe controller has two adjustment pods. You need a miniscrew driver to adjust these. One is speed and one is gain.These are noted on the drawing of the controller.

BOARDREFER TO WIRING THEDIAGRAM FOR CONNECTIONSTHRU THE WIRING HARNESS 1\'-

~ , ~ ~ ~ ~ ~ ~ t ~ B ; ~ O A R OSIIirt the engine. The speed should be in the low idle range600-700 rpm. I f he engine speed is higher than this idlerange, shut the engine down. Check the linkage betweenthe actuator and throttle arm. The throttle arm stop shouldbe about touching the open idle stop screw boss. Adjust thelinkage to position the throttle lever. Restart the engine andusing the speed adjustment buttons bring the engine speedto 1800 rpm (60Hz), 1500 rpm (50Hz). Momentarily pushthe actuator linkage towards the actuator and release. Theactuator should quickly regain proper speed. I f here is anyhunting, adjust the gain towards zero (0) until this huntingis removed.When the gain is adjusted, you may need to re-adjust thespeed at no load, shut the generator down.Start the generator.Check speed (hertz) set at 50Hz/60Hz.Load the generator.I f the governor is slow to react and maintain 50Hz/60Hz,adjust the gain clockwise. Again you may need to adjustthe speed at nO load.You will find the governor will maintain set engine RPM 0.5 Hz right up to the full rated amperage output for thegenerator.

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THE ELECTRONIC GOVERNORMAGNETIC PICK-UP [MPUIINSTALlATIONThe MPU is installed in the threaded opening on the sideof the flywheel bellhousing. This positions the MPU overthe teeth of the flywheel ring gear.Viewing through this opening, manually rotate the enginecrankshaft so as to position the flat of one of the ringgear's teeth directly under the opening. Thread the MPUinto the opening until it gently contacts the flat of thistooth (Thread is 3/8" x 24). Back the MPU out of theopening one turn and then lock it in this position with thejam nut. This will position the end of the MPU .approximately 0.030 inches away from the flats of the nnggear teeth.To ensure the MPU is positioned correctly, slowly rotatethe crankshaft by 360 by hand to assure there is nophysical contact between the MPU and the ring gear teeth.I f contact is felt between the MPU and the flywheel teeth,the MPU may be damaged. Remove the MPU and inspectit. Replace i f necessary and repeat the aboveinstallation procedure.NOTE: When replacing tile Magnetic PickUp (MPU) itMUST be replaced without cutting and splicing into tileexisting wiring cable. Doing so will cause a e"atic ACsignal to tile controller.

WIRES K.upAf f # ~ : } f ~ ~ ~ ~ ~ ~ " , , " , M P U ' M A ( I N E T l C P I C ~~ 0.0301n- -

GOVERNOR CIRCUIT VOLTAGESBelow are the voltages nonnaUy found in the governorcircuit when the system is functioning normally. Thesevoltages are an approximate and should be of help introubleshooting a system that is not functioning correctDC Voltage into ControllerBat+ to Bat (battery charging voltage 13.5 . 14.5 VD(Terminal block #1 and #2)DC Voltage to ActuatorACT to ACT (5.5 6.5 VDC)(Terminal block #5 and #6)AC Voltage from MPU into ControllerMPU to MPU (2.5 - 7.0 VAC)(Terminal block #3 and #4)This voltage spread is the result of the distance the MPUpositioned from the flat of the flywheel ring gear tooth.The closer to the tooth, the higher the AC signal. Thefurther away, the lower the AC signal.

ACTUATOR "OHM VALUE"12 VOLT PN#044990 3.0-3.1 OHM

PN#303007 2.0 - 2.1 OHM24 VOLT PN#044991 10.7 - 10.8 OHM

PN#039746 7.5 -7.6 OHM

MPU (MAGNETIC PICKUP "OHM VALUE"PN#039172 .950 - 1.0 K OHM

~ WESTERBEKEEngines & Genemtors

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ProblemSystem appears dead.(No actuator movement)Engine runs, but at idle speed

Actuator lever goes to fullextension when the preheatswitch Is depressed and staysextended.

ELECTRONIC GOVERNOR TROUBLESHOOTINGTestlCheck

1. Check the battery voltage at the controller terminal blockwith the PreheatfOn switch depressed.2. Inspect the linkage for binding or sticking,3. If there is no sIgnal or aweak signal from theMPU, measure the AC voltage between the whileand blacklwhile wire leads from Ihe MPU on Ihe conlrollerterminal block. While cra:nking the engine or with the enginerunning al Idle, voltage should be 1.5-2.5 VAC.NOTE: The AC input impedance of meter must be50000hmS/Volfs or greater.NOTE: When making this test on diesel units, disablethe preheat solenoid by disconnecting the "5" terminalconnection so as not to damage the glow plugs.

4. Check the actuator with the preheat/on switch depressed.This provides DC voltage to the controller. Measure theDC voltage between the actuator connections on thecontroller block and the black DC H power connectionon the controller terminal block. Both connections shouldhave battery voltage +0.00 or 0.75 VDC.a. Purple lead to Black DC (-).b. Purple l e a d J p u r p l e t w h ~ e lead to Black DC (-).NOTE: Conlinu, this test (ONLY) if he batteryvoltage Is not present.c. The following checks are performed between theconnections at the actuator and the Black DC (-) connectionon the controller terminal block. This is to determine if thereis abreak in the line between the controllers terminal blockconnection and the actuator connections or the actuatorleads themselves.

1) Low voltage (1.0-2.0 VDC) at either actuator connections.2) Battery voltage at both actuator connections,3) Battery voltage at one actuator connection butnot at thesecond.

1. Check the controller by removing the two. purple leadsone at a ime that come from the actuator off the controlierterminal block. Lift one actuator lead and depress thepreheat/on switch, Reconnect and do the same with the second.NOTE: Early controllers had two solid purpfB leads for theactuator connections. Later model controllers have one solidpurple andapurple/white stripe for the actuator connection.The purplBlwhite lead Is designated (+) and is speclffc only ingasoline DC circuits.a. Actuator goes to full extension (Diesel) Does not retract (Gasoline),b. Actuator does not extend (Diesel).

Correct1. Inspect the DC circuit back to the starting battery.2. Free up the linkage and clean and lubricate the linkage.3. Check for damage to or improper adjustment ofmagnetic pick-up. Replace or re-adjust.

4. Low voltage (1,0-2,0 VDC) at either actuator connections.

b. Replace the controller If battery voltage Is not present atboth the Purple leads.

1) Broken actuator lead, repair,2) Broken actuator lead, repair or replace actuator.S) Check actuator winding for open. Replace actuator.

1. Check for ashorted actuator lead. Replace thecontroller because it should not cause the actuatorlever to go to full fuel when the engine is not running.

a. Check for shorted actuator load.b. Replace controller.

Actuator hunts dunng operation. 1. Linkage or rod end bearings are sticking or binding.2. Improper governor adjustment.

1. Lubricate or replace,2. Re-adjust the calibration.S. Inadequate power supply voltage. Connect aDC voltmeter to Red (+) and Black (.) leadsat the controller terminal block.b. Disconnect both leads coming from actuator fromcontroller terminal block.c. Connect one lead from the actuator to the Red (+)on the terminal block and the other actuator lead tothe Black (-)on the terminal block.d. Momentarily depress the preheat/on switch. The actuatorshould extend fully and stay extended (diesel) andretract (gasoline) as long as the switch is depressed.

S. It actuator doesn't f u l ~ extend (diesels) or retract(gasoline)then check the actuator leads.If the voltage is less than specified, check forloose or poor connections in the DC circuit back tothe battery, check the K2 relay and its connections.

Measure the DC voltage across the Red r+) and Black (.)leads while rerforming this test. DC voltage must be greaterthan 80% 0 the DC voltage measured across the battery s u p p ~ .24 VDC@ 80% = 19.2 VDC12 VDC@80% =9.6 VDC

NOTE: Reconnect the actuator leads properly after completing this test.e. MPU positioned marginally too far away from flywheel e. Check the position of the MPU.teeth giving erratic AC Input to controller,

II problems continue to persist, contact your WESTERBEKE dealer lor addillonal asslslance,

Engines & Generators3t:


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THE ELECTRONICDESCRIPTIONA generator's engine must run at a constant speed to enablethe generator to produce the stable AC power (hertz)required.The Electronic Governor consists of three compenents, theCONTROllER, a pc board installed in the control panel. AMAGNETIC PICKUP (MPU) installed in the bellhousing overthe engine flywheel and the linear ACTUATOR mounted on theengine and attached by linkage to the injection pumpthrottle control.The Electronic Governor regulates the engine speed bysensing the engine's RPM with the magnetic pick-up at theflywheel. The governor's controller continuously monitorsthe engines speed and if there is any discrepancy, thecontroller signals the actuator and the actuator adjusts theengine to the desired speed electronically.CONTROLLER ADJUSTMENTThe controller has two adjustments: the SPEED adjustmentis used to increase or decrease the the engine's speed to thedesired hertz. The GAIN adjustment affects the reactiontime of the actuator to the generator load changes.NDlE: A high gain adjustment can induce an oscillatingof he actuator producing a hunting mode. In such cases,lessen the gain adjustment.CALIBRATION1. With no pewer to the governor (engine not running),adjust the GAIN potentiometer to 9:00 o'clock.2. Start the engine.The green LED will indicate thegovernor is energized. Adjust the controller for thedesired speed by pressing the decrease or increase

buttons.NOTE: Controllers are factory adjusted to minimumRPM. However, for safety, one should be capable ofdisabling the engine if an overspeed should exist.3. At no load, turn the GAIN potentiometer clockwiseuntil the engine begins to hunt. I f he engine does nothunt, physically upset the actuator linkage.4. Turn the GAIN potentiometer counterclockwise untilengine rons stable.

NOTE: The controller operates with either 12 or 24VDC.The minimum voltage the controller must have tooperate is 9.0VDC. The maximum voltage the controllerwill operate with is 30VDC. If he DC voltage fallsbelow the minimum or above the maximum, thecontroller will not operate until the voltage problem iscorrected.NOTE: High DC voltage will damage the controller.

ELECTRONIC GOVERNOR ADJUSTMENTSWhen you press the preheat switch, the actuator linkageattached to the throttle arm of the injection pump shouldmove outward towards the injection pump and return backinto the actuator in a quick motion on diesel models andpuIl in and hold in on gasoline models.

LINEAR ACTUATORl ~ ~ ~ t c Z ~ ; ; ; c WELL

#OONAGNIETIC PIC

THROTTLE LINKAGE VARIES WITH DIFf'ERE,lfj6;ENI'RStart the engine. The speed should be in the low idle range600700 rpm. I f he engine speed is higher than this idlerange, shut the engine down. Check the linkage betweenthe actuator and throttle arm. The throttle arm stop shouldbe about touching the open idle stop screw boss. Adjust thelinkage to pesition the throttle lever. Restart the engine' andusing the speed adjustment buttons bring the engine speedto 1800 rpm (60Hz), 1500 rpm (50Hz). MomentariIy pushthe aptuator linkage towards the actuator and release. Theactuator should quickly regain proper speed. I f there is anyhunting, adjust the gain towards zero (0) until this huntingis removed.When the gain is adjusted, you may need to re-adjust thespeed at no load, shut the generator down.Start the generator.Check speed (hertz) set at 50Hz/60Hz.Load the generator.I f he governor is slow to react and maintain 50Hz/60Hz,adjust the gain clockwise. Again you may need to adjustthe speed at no load.You will find the governor will maintain set engine RPM 0.5 Hz right up to tlie full rated amperage output for thegenerator.~ WESTERBEKE

Engines & Generators1 (\


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THE ELECTRONIC GOVERNORMAGNETIC PICKUP (MPU] INSTALLATIONThe MPU is installed in the threaded opening on the sideof the flywheel bellhousing. This positions the MPU overthe teeth of the flywheel ring gear.Viewing through this opening, manually rotate the enginecrankshaft so as to position the ftat of one of the ringgear's teeth directly under the opening. Thread the MPUinto the opening until it gently contacts the ftat of thistooth (Thread is 3/8" x 24). Back the MPU out of theopening one turn and then lock it in this position withthe jam nut. This will position the end of the MPUapproximately 0.030 inches away from the flats of thering gear teeth.To ensure the MPU is positioned correctly, slowly rotatethe crankshaft by 360 by hand to assure there is nophysical contact between the MPU and the ring gear teeth.I f contact is felt between the MPU and the flywheel teeth,the MPU may be damaged. Remove the MPU and inspectit. Replace if necessary and repeat the aboveinstallation procedure.NOTE: When replacing the Magnetic Pick-Up(MPU) itMUST be replaced without cutting and splicing into theexisting wiring cable. Doing so will cause a erratic ACsignal to the controller.

GOVERNOR CIRCUIT VOLTAGESBelow are the voltages normally found in the governorcircuit when the system is functioning normally. Thesevoltages are an approximate and should be help introubleshooting a system that is not functioning correctly.DC Voltage into ControllerBat+ to Bat - (battery charging voltage 13.5 - 14.5 VDC)DC Voltage to ActuatorACT to ACT (5.5 - 6.5 VDC)AC Voltage from MPU into ControllerMPU to MPU (2.5 -7.0 VAC)This voltage spread is the result of the distal)ce the MPUpositioned from the flat of the flywheel ring gear tooth.The closer to the tooth, the higher the AC signal. Thefurther away, the lower the AC signal.

ACTUATOR "OHM VALUE"12 VOLT PN#044990 3.0 - 3.1 OHM

PN#303007 2.0 - 2.1 OHM24 VOLT PN#044991 10.7 - 10.8 OHM

PN#039746 7.5 - 7.6 OHM- ~0.03010

- --MPU (MAGNETIC PICKUP "OHM VALUEPN#039172 .950 - 1.0 K OHM

~ WESTERBEKEEngines & Generators

2h


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ProblemSystem appears dead.(No actuator movement)Engine runs, but at Idle speed

Actuator lever goes to fullextension when the preheatswitch Is depressed and staysextended.

Actuator hunts during operation.

ELECTRONIC GOVERNOR TROUBLESHOOTINGTesllCheck

1. Check the baHel)' voltage at the controller terminal blockwith the PreheaVOn swllch depressed.2. Inspect the linkage for binding or sticking.3. If there is no signal or aweak signal from theMPU. measure the AC voltage between the whiteand black/whlte wire leads from the MPU on the controllerterminal block. While cranking the engine or with the enginerunning at idle, voltage should bo 2.53.0 VAC.NOTE: The AC input impedance ofmeter must be5000 ohms/Voffs or greater.NOTE: When making this test on diesel units, disablethe preheat solenoid by disconnecting the US" terminalconnection so as not to damage the glow plugs.

4. Check the actuator with the preheaVon switch depressed.This provides DC voltage tQ the controller. Measure theDC voltage between the actuator connections on thecontroller block and the black DC (-) power connectionon the controller terminal block. Both connections shouldhave baHel)' voltage +0.00 or '0.75 VDC.a. Purple lead to Black DC (.).b. Purple lead/purplelwhitolead to Black DC (.).NOTE: Continuu this tust (ONLY) Ifthu bafferyvoltage is not present.Co The following checks are performed between theconnections at the actuator and the Black DC (-) connectionon the controller terminal block. This Is to dotermlne it thereis abreak in the line between the controllers terminal blockconnection and the actuator connections or the actuatorleads themselves.

1) low voltage (1.0-2.0 VDC) at either actuator connections.2) BaHel)' voltage at both actuator connections.3) Battery voltage at one actuator connection butnot at the second.

1. Check the controller by removing the two. purple leadsone at a ime that come from the actuator off the controllerterminal block. Lin one actuator lead and dopress thepreheat'on switch. Reconnect and do the same with the second.a. Actuator goes to tull oxtenslon (Dlesol),.Does not retract (Gasoline).b. Actuator does not extend (Diesel).

1. linkage or rod end bearings are sticking or binding.2. Improper governor adjustment.3. Inadoquate power supply voltage... Connect aDC vonmeter to Red (+) and Black (.) leadsat the controller terminal block.b. Disconnect both leads coming from actuator fromcontroller terminal block.Connect one lead from the actuator to the Red (+)on the terminal block and the other actuator lead tothe Black (-)on the terminal block.d. Momentarily dewess the preheat/on switch. The actuatorshould extend f u l l ~ and stay extendod (GasOline) andretract (Diesel) as long as the switch is depressed.Measure the DC voltage across the Red (+) and Black (.)leads while porlorming this test.

9.0 VDC minimum30.0 VDC maximum

Correct1. Inspect the DC circutl back to the starting baHel)'.2. Free up the linkage and clean and lubricate the linkage.3. Check for damage to or Improper adjustment ofmagnetic pick-up. Replace or re-adjust.

4. low voltage (1.0-2.0 VDC) at either actuator connections.

b. Replace the controller if battery voltage is not present atboth the Purple leads.

1) Broken actuator lead, repair.2) Broken actuator lead, repair or replace actuator.3) Check actuator winding for open. Replace actuator.

1. Check for ashorted actuator lead. Replace thecontroller because it should not cause the actuatorlever to go to full fuel when the engine is not running.a. Check for shorted actuator load.b. Replace controller.

1. lubricate or replace.2. Re-adJust the calibration.3. If actuator doesn't fully extend (diesel) or retract(gasoline)then check the actuator leads.If the voltage Is less than specIfied, check forloose or poor connections In the DC circuit back tothe battery, check the K2 relay and its connections.

NOTE: R8conn8ct the actuator 18ads prop8rly aft8r compl8ting this test.o. MPU positioned marginally too far away from flywheel o. Check the position of tho MPU.teeth giving erratic AC input to controller.

II problems conllnue to perslsl, contact your WESTERBEKE dealer lor additional asslslance.

~ WESTERBEKEEngines & Generstors

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..fL'ECTRONIC GOVERNOR TERMINAL CONNECTION

VOLTMETER12 VDC

DC+,

DC.:.

RED)

BLACK

BLACK + WIRESENSOR

RED

PURPLE

ACTUATOR ..PURPLE

ACTUATOR "OHMVALUE"12 VOLT PN#044990 3.0 -3,1 OHM

PNH303007 2.0 - 2.1 OHM24 VOLT PN#044991 10.7 - 10.8 OHM

PN#039746 7.5 - 7.6 OHM

RED.{YBLACK~

\.Y

BLACK/WH ITE-&

WHITE.

Electronic Governor Troubleshooting Guide Rev a 03 2008

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Transcript of Electronic Governor Troubleshooting Guide Rev a 03 2008