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  • Electronic Governor Troubleshooting Guide - Non-Digital Diesel

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    Clifton Jamison
    244 просмотров13 страниц
    A guide put out by Westerbeke to troubleshoot non-digital diesel governor systems.

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    Electronic Governor Troubleshooting Guide - Non-digital Diesel

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    A guide put out by Westerbeke to troubleshoot non-digital diesel governor systems.

    Авторское право:

    © All Rights Reserved
    Скачайте в формате PDF или читайте онлайн в Scribd
    Отметить как неприемлемый контент
    244 просмотров13 страниц

    Electronic Governor Troubleshooting Guide - Non-Digital Diesel

    Загружено:

    Clifton Jamison
    A guide put out by Westerbeke to troubleshoot non-digital diesel governor systems.

    Авторское право:

    © All Rights Reserved
    Скачайте в формате PDF или читайте онлайн в Scribd
    Отметить как неприемлемый контент
    из 13
    ° : Ri —< ELECTRONIC GOVERNORS ANALOG DIESEL MODELS ~ ADJUSTMENTS / CALIBRATION . AND. COMPONENT TROU ESHOOTING pple TABLE OF CONTENTS ELECTRONIC GOVERNOR (BARBER COLMAN) ELECTRONIC GOVERNOR (WARDWARD) Generator Models to June 2004 Description... 1. | Description 6 Controller Adjustment. 1 | Controller Adjustment. 6 Calibration....... 1 .| Calibration... 6 Electronic Governor Adjustments. 1 | Electronic Governor Adjustments 6 Magnetic Pick-Up (MPU) Instaltati 2 | Magnetic Pick-Up (MPU) Installatio 7 2 | Governor Circuit Voltages 7 2 | Actuator OHM Values... 7 3 | Electronic Governor Troubleshootin, 8 4 9 4 9 Nominal Circuit Voltages ..... 5 | ‘Nominal Circuit Voltages 10 CES] WESTERBEKE. Engines & Generators THE ELECTRONIC GOVERNOR (BARBER COLMAN) GENERATOR MODELS TO JUNE 2004 DESCRIPTION A generators engine must run ata constant speed to ene the generator to produce the stable AC power (hertz) required, “The Becronic Goverat consists of three component, the CONTROLLER, 2 pc board installed in the control panel. A. MAGNETIC PICK-UP (MPU) installed in the bellhousing over the engine flywheel andthe linear ACTUATOR moantd onthe ‘engine and attached by linkage to the injection pump throtle conto “The Electronic Goverar regulates th engine spoed by sensing th engine's RPM with the magne pick-up atthe flywheel The governor's controller continuously monitors the engines speed and if there is any discrepancy, the controller signals the acuator and the aczutor adjusts the engine tothe desired spend electronically. CONTROLLER ADJUSTMENT ‘The controller has two adjustments: the SPEED adjustment ‘is used to increase or deorease’the the engine's speed to the desired hertz. The GAIN adjustment affects the reaction time of the actuator to the generator load changes. NOTE: A high gain adjustment can induce an oscillating of the actuator producing a hunting mode. In such cases, lessen the gain adjustment. CALIBRATION 1. With no power to the govemor (engine not running), adjust the GAIM potentiometer to 9:00 o'clock. 2, Start the engine and adjust the speed by turning the speed pod clockwise to desired speed, NOTE: Condrolters ae factory adjusted to minimum RPM. However, for safety, one should be capable of disabling the engine ian overspeed should exist. 3. Ato load, turn the BAIN potentiometer clockwise ‘until the engine begins to hunt. Ifthe engine does not hhunt, physically upset the actuator linkage 4, ‘Dum the GAIN potentiometer counterclockwise until engine rans stable, NOTE: Controllers are available in 12 and 24 VDC models. The operating voltage range is + or ~ 20%, If the voltage varies above or below this range, the controller will not operate and the engine wil run in the idle mode until proper DC voltage is supplied to the controller ELECTRONIC GOVERNOR ADJUSTMENTS ‘The controller has two adjustment pods. You need a mini screw driver to adjust these. One is speed and one is gain. ‘These are noted on the drawing of the controller. Coy IWESTERREKE Engines & Gonerators 1 MAGHETIC PICK-UP taPu REFER TO WIRING THE. DIAGRAM FOR CONNECTIONS THAU THE WIRING HARKESS LINEAR ACTUATOR TyPloat THROTTLE Start tie engine. The speed sould be in the low idle range {600-700 rpma. Ifthe engine speed is higher than this idle range, shut the engine down. Check the linkage between the actuator and throttle arm, The throttle arm stop should ‘be ebout touching the open idle stop screw boss. Adjust the linkage to postion the throttle ever. Restart the engine and using the speed adjustment butons bring the engine speed to 1800 rpm (601HZ), 1500 rpm (50H). Momentaily push the actuator linkage towards the actuator and release. The ‘actuator should quickly regain proper speed. If there is any hhunting, adjust the gain towards zero (0) unt this hunting is removed. ‘When the gain i adjusted, you may need to re-adjust the speed at no load, shut the generetor down, Star the generator (Check speed (her) set at SOH2/60Hz, Load the generator IE the governor is slow to react and maintain SOTIZ/60Hr, adjust the gain clockwise, Again you may nced to adjust the speed at no load. ‘You will find the governor will maintain set engine RPM. + 0.5 Haight up tothe full reted amperage output for the generator ELECTRONIC GOVERNOR MAGNETIC PICK-UP [MPU] INSTALLATION “The MPU is installed inthe threaded opening on the side Of the flywheel bell housing. This positions the MPU over the tect ofthe flywheol ring gear. ‘Viewing through this opening, manually rotate the engine crankshaft so a5 to postion the flat of one ofthe ring ‘gear’ teoth droclly under the opening. Thread the MPU {nto the opening unt it gently contacts the flat of this tooth (Thread is 3/8” x 24) Back the MPU out ofthe ‘opening one turn and then lock i in this postion with the jam nut. This will position the end of the MPU approximately 0,030 inches away from the flts of de ring gear teth “To ensure the MPU is positioned correctly, slowly rotate the erankshatt by 360° by hand to assure there is no ‘physical contact between the MPU and the ring gear teeth If contact is felt between the MPU end the flywheel tet, ‘the MPU may be damaged. Remove the MPU and inspect it, Roplace if necessary and repeat the above installation procedure. MOTE: ffreplacing the Magnetic Pick-Up (MPU) it MUST bbe replaced without cuting and splicing into the existing wiring cable. Doing so will cause a erratic AC signal to the controler MPU (waaMETIC Pic PN. ouot72 960 JP) “OHM VALUE” OHI GOVERNOR CIRCUIT VOLTAGES: Below are the voltages normally found in the governor ircuit when the system is functioning normally. These voltages are an approximate and should be of help in troubleshooting a system that is not functioning correctly. DC Voltage into Controlter Bat + t0 Bat- (battery charging voltage 13.5 - 145 VDC) (Terminal Block #1 and #2) DC Voltage to Actuator ACT to ACT (5,5 - 6.5 VDC) (Terminal block #5 and #6) AC Voltage from MPU into Controller MPU to MPU (2.5 - 7.0 VAC) (Terminal block 34 and #4) ‘This voltage spread is the result ofthe distance the MPU is positioned from the flat of the flywheel ring gear tooth. ‘The closer tothe tooth, the higher the AC signal. The further away, the lower the AC signal ACTUATOR “OHM VALUES” 12 Volt PN044990 3.0 - 3.1 OHM PN 303007 2.0- 2.1 0HM PN044991 10,7 - 10.8 OHM PN 039746 7.5 - 7.6 OHM 24 Nott ELECTRONIC GOVERNOR TROUBLESHOOTING (253 Problem TestiCheck. Comect “ System appears dead. 1. Check DC voltage present at terminal block, 1. Inspect the DC circuit back to the source. * Engine rus, but tide speed Battery voape shouldbe present at and #2, 2, Inspeot extemal tnkage for binding or sticking 2. frequp the inkape and clan and licata e ‘3 Check AG signal from MPU at terminal block #2 and #3 8, Inspect MPU cireult. Check MPU coll AC voltage 1.5 - 2.5 VAG. {88ianes and contin. No damage to i. 4. Check DG voltage at actuator connections ‘9n terminal block. #5 and #2, #6 and #2 VAC. 4, Check actuator circuit. f battéry vottage 12 VDC should be present. isnot present, replace the controller, 5. Battery voltage present between #5 and #2, 5. Check actuator directly with 12 VDC. #8 and #2, heck winding, Replace actuator i needed. Entemal Actuator goes info 4. Check the controller by lifting the actuator leds, full edension when preheat” one at a time off the terminal block and depress is daoressed and stays re-hat. extended. Actuator goes to full extension. 1. Check for shortad lato actuator. Actuator does not extend ‘Replace control Exteiral Actuator hunts during 4, Linkage are sticking or binding. 1. Lubricate or replace. rrormal operation. a 2. Improper controller adjustment. 2. Re-adjust the calibration and lower the GAIN adjustment. 3. Low DC voltage to controller 3, Check the DC voltage at the terminal block #1 and #2. Charging voltage should be present, 24 VOC min is 19.2 VOC 42VDC mins 9.6 VOC 4. MPU is positioned to far from the flywheel 4. Chack MPU. ring gear or tip of MPU is contaminated, IWESTERBEKE Engines & Generators, INTERNAL ACTUATOR TROUBLESHOOTING THREAD IN TYPE DESCRIPTION ‘The actyator is threaded into the engine block behind the engines fuel infection pump. The operator can not seescen visually. When static, the actuator plunger is extended and ‘keeping the fuel injection pamp's fuel rack in the no-fuel delivery position. ‘An engine cranking with no start can be the result ofthe actuator not functioning due to a faulty actuator or the actuator not receiving DC voltage from the controller 0 raw its plunger away from the fuel rack, Troubleshooting 1, Cranking with no start 1. Check for fuel delivery 1 the injectors. 2. Check DC voltage to the actuator while cranking. Tectninal blooks #5 to. 46 03 -1.0 VDC. 3:No DC voltage faulty controller, DC voltage, Faulty actuator, Remove and test extemally. The following instructions are for adjusting or replacing the actuator, 1, Shut-off the DC power to the generator. 2, Disconnect yhe actuator wires from the wiring harness. 3. Measure the distance between the actuator and the ‘engine mounting surface as shown. ENGINE MOUHTING 4, Back-off the 17/16” jam nut and unscrew the actuator, ‘5. Test the actuator by applying 12 VDC across its two electrical connections. Plunger should be fully in 6. To replace/re-install the actuator. Apply a small amount of liguid Teflon sealant to the threads ahead of the jam. nut and thread the actuator into the block. Maintain the same distance as in step #3 (standard distance 13/16" to 7/8"). Secure the actuator with the jamn not 7, Re-connect the actuator wiresto the hamess and test run the generator. WOTE: Ifthe unit does not shut down property (goes to low tale), loosen the jam mut and turn the actuator in 18-114 of a ‘urn until the proper shut-down is achieved. ZJWESTERBEKE & Gonerators NOMINAL CIRCUIT VOLTAGES TERMINAL BOARD NUMBERS 1 THRU 6 ‘TERMINAL #1 TO #2, 12.5 VDC (Battery Voltage) TERMINAL#5 TO #6 0.5 VDC CTERMINAL/VOLTAGE VDC ‘TERMINAL #1 TO #2 115 VDC (Battery Voltage) ‘TERMINAL #3 TO #4 15-25 VAC = ‘TERMINAL #5 TO #6 0.5 VDC ‘TERMINAL #1 TO #2 135 - 141 VDC (System Charging Voltage) ‘TERMINAL #370 #4 4'~7 ° VAC TERMINAL #5TO #6 50-7.0 VDC GOVERNOR CONTROLLER ACTUATOR NOTE: One of the purple leads from the governor controller ‘may have a white stripe IWESTERBEKE. Engines & Gonoratore WOODWARD -MODEL DESCRIPTION A genemitors engine mus run ata constant speed to enable the generator to produce the stable AC power (hertz) required ‘The Electronic Govemor consists of three components, the ‘CONTROLLER, a pc bosrd installed in the contol panel. A MAGNETIC PICK-UP (VIPU) installed in the belhousing over the engine flywheel and the linear ACTUATOR mounted on the ‘engine and attached by linkage tothe injection pump throttle control ‘The Hlentonic Govemar regulates the engine speed by sensing the engine’s RPM with the magnetic pick-up st the flywheel The governors eonttollercontinuovsly monitors the engines speed and if here is any discrepancy. thé controler signals the actuator and the actuator adjusts the engine tothe desired speed electronically. CONTROLLER ADJUSTMENT ‘The controler has two adjustments: the SPEED adjustment is used to increase or decrease the the engine's speed to the desired hertz. The GAN adjustment affects the reaction ‘time of the actuator to the generator load changes. NOTE: 4 high gain adjustment can induce an oscillating of the actuator producing a hunting mode. In such cases, lessen the gain adjustment CALIBRATION 1. With no power tothe governor (engine not running), Depressing the Start switch andthe starter cranks the adjust the GAIN potentiometer to 9:00 o'clock. cagine, the MPU sends a ioiy AC signal to the edntrolier 2, Start the engine and adjust the spoed by tung the aac the controller in turn sends a DC voltage tothe speed pod clockwise to desired speed. actuator moving the throte arm (extemal) or pungéc away from the fuel rack intemal allowing for fel NOTE: Controllers are factory adjusted t0 minimum delivery to the injectors and a star. Engine specd will RPM, However, for safety, one should be capable of inorease until the set AC voltage signal from the MPU is alsabling the engine fan overspeed should exist achieved and the controller wil then vary the DC vetage 3. Atno load, tum the GAIN potentiometer clockwise to the actuator increasing or decreasing fuel delivery to ‘until the engine begins to hunt. If the engine does not maintain this MPU AC signal under all load conditions. hunt, physically upset the actuator Linkage. With the installation of a new replacement controller, the 4, Turn the GAIN potentiometer counterclocktvise uni programmed speed at startup Will be in the 1000-1500 engine runs sabe, fpm range. The speed ean then be adjusted as needed by NOTE: Controtters are available in 12 and 24 VDC ‘momentary depression ofthe Speed Buttons to increase or ‘models, Te operating voltage range 1s + or ~ 20%. If Ps the voltage varies above or below this range, the Once the proper rpa/hertz is achieved, extemal actuators, controller wil not operate and the engine wil ra in bump the linkage towards the actuator, ntoral actuators the idle mode until proper DC voltage is supplied 10 put an amperage load on the generator and take it off the controller If there is any hunting induced by doing this, adjust the GAIN towards zero (0) until this hunting is ELECTRONIC GOVERNOR ADJUSTMENTS removed. When the gain is adjusted, you may need to re- Pressing the pre-heat switch, the LED Indicator ight {just the speed at to load, shut he generator dwn. (green) on the controler wil stat to blink indicating the ‘Seat cama Conttoller has the proper DC voltage to operate. (Check speed (hertz) set at SOEEZ/6OH. Load the generator If the governor is slow to react and maintain SOHZ/60H, adjust the gain clockwise. Again you may need to adjust the speed at no load., WESTERBEKE ‘Engines & Generators ELECTRONIC GOVERNOR ‘(MAGNETIC PICK-UP [MPU] INSTALLATION ‘The MPU is installed inthe threaded opening on the side of the flywheel bell housing. This positions the MPU over the teeth ofthe flywhe! ring gear. ‘Viewing trough this opening, mamzally rotate the engine crankshaft so as to position the flat of one of the ring gears teth dicecly under the opening. Thread the MPU {into the opening until it gently contacts the flat ofthis tooth (Thread is 3/8” x 24) Back the MPU out of the ‘opening one tur and then lock it in this position withthe jam nut, This will postion the end of the MPU approximately 0.030 inches away from the flats of the ring gear teeth, ‘To ensure the MPU is positioned cozrecty, slovy rotate the crankshaft by 360 by hand to assure thero is no physical contact between the MPU and the ring gear teeth. Tf contacts felt between the MPU and the flywheel teeth, the MPU may be damaged. Remove the MPU and inspect it, Replace if necessary and repeat the above installation procedure, NOTE: If replacing the Magnetic Pick-Up (MPU) it MUST be replaced without cutting and splicing into the existing wiring cable, Dong so will cause a erratic AC signal 19 the controller [MPU (HAGMETIC PICK-UP) “ona VALUE” Pu. a96172 .850-1.0K OHM GOVERNOR CIRCUIT VOLTAGES Below are the voltages normally found in the govemor iteuit when the system is functioning normally. These voltages are an approximate and should be of help in troubleshooting a system that is not functioning correctly. DC Voltage into Controller Bat +-to Bat - (battery charging voltage 13.5 - 14.5 VDC) (Terminal Block #1 and #2) ‘DC Yoltage to Actuator ACT to ACT (5,5 - 6.5 VDC) (Terminal block #5 and #46) AC Voltage from MPU into Controller ‘MPU to MPU (2.5 - 7.0 VAC) (Terminal block 3# and #4) ‘This voltage spread is the result of the distance the MPU is positioned from the flat of the flywheel ring gear tooth, ‘The closer to the tooth, the higher the AC signal. The further away, the lower the AC signal. ACTUATOR “OHM VALUES” 12Volt PN 044990 3.0-3.1 OHM PN 303007 2.0-2.1 OHM 24Volt PN044991 10.7 - 10.8 OHM PN 039746 7.5 -7.6 OHM ELECTRONIC GOVERNOR TROUBLESHOOTING (Wooowano) t Prablem ‘System appears dead Engine runs, but at ile spaed External Actuator goes into {ull extension when prefeat is depressed and stays . edended, (Actuators plunger should not extend). ‘Extamal Actuator hunts during 4. ‘normal operation. ‘Testicheck 41. Check DC voltage present at terminal block. Battery voltage should be present. #1 and #2. Gorrect ‘TcInspect the DC circuit back to the source. 2, Inspect external linkage for binding or sticking. 2. Free upthe tinkage and clean and lubricate ‘the linkage. 3. Check AC signal from MPU at terminal block #2 and #3. AC voltage 7.5 - 2.5 VAC. 4. Check DG voltage at actuator connections 3. Inspect MPU circuit. Check MPU coil {stance and conan. No damage to ip. on terminal block. #5 and #2, #6 and #2 VAC. 4. Cheok actuator circuit If battery voltage 12.VDE should be present 5. Battery voltage present between #5 and #2, #5 and 4. 12 VOC between #5 and #6 Linkage are sticking or binding, 2. Improper controlisr adjustment. 3. Low DC vottage to controler. 4, MPU is positioned to far from the fywheal ‘ing dear or tip of MPU is contaminated, IWESTERBEKE_ ‘Engines & Generalors 's not present, replace the controle. 5. Check actustor directly with 712 VOC. hook winding. Replace ecuator needed. 1. Replace controller. 4. Lubricate or replace. 2. Re-adlust the calibration and lower the GAIN adjustment. ‘8. Check the DG voltage at the terminal block #1 and #2. Charging voltage should be present. 24 VDC minis 19.2 VOC 412 VDC minis 9.6 VOC 4. Check MPU. INTERNAL ACTUATOR TROUBLESHOOTING THREAD IN TYPE DESCRIPTION ‘The actuator is threaded into the engine block bend the ‘eagines fv! injection pump. The operator can not soeseen visually, When staic, the actuator plunger is extended and -eeping the fuel injection pump’s fuel rack inthe no fuel delivery postion. ‘An engine cranking with no start can be the resi of the actuator not functioning due toa faulty actuator or the actuator not receiving DC voltage from the controller to draw its plunger away from the fuel rack. Troubleshooting 1. Cranking with no start. |. Check for fuel delivery tothe injedtots. 2. Check DC Voltage to the ‘actuator-while cranking. ‘Tecminal blocks #5 to:#6 05-10vbe: 3. NODC voltage faulty controlisé; DC voltage; Faulty actuator, Remove and test externally. AINUSTMENTS The following instructions are for adjusting or replacing the actuator, 1. Shutoff the DC power to the generator. 2, Disconnect yhe actuator wires from the wiring hamess, 3. Measure the distance between the actuator end the engine mounting surface es shown, EWGWE MOUNTING ssronon Hesse “a RUT FERENCE 4, Buckoff the 1 7/16” jam mut and unscrew the actuator, 5, Test the actuator by applying 12 VDC across its two

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