Manual SDG725

SDG700
Smarrtt Sma Diigiittall Dg a Goverrnorr Gove no
SERIES
OPERATING MANUAL
SDG72X Series
G o v e rr n o rr s A m e rr ii c a C o rr p .. Gove no s Ame ca Co p
5/10/01 Page 1 of 23 REVD
SDG700
SERIES
TABLE OF CONTENTS
SDG Introduction ........................................................................ 4 CHAPTER 1: SDG Installation
Connections and Wire Types. ........................................................... 5 Accessories. ...................................................................................... 6 Load Sharing and Synchronizing Input.............................................. 6 Magnetic Pickup Sensor.................................................................... 6
CHAPTER 2: User Interface

Menu of Functions............................................................................. 7 Display Modes................................................................................... 8
CHAPTER 3: Configuring SDG

Configuring SDG and Accessing Setup Mode................................... 9 Flywheel (Ring Gear) ........................................................................ 10 Overspeed......................................................................................... 10 Speed Settings (Fixed and Variable)................................................. 11 Crank Termination Setting................................................................. 12 Starting Fuel Control. ........................................................................ 13 Speed Ramping................................................................................. 14 Droop Settings................................................................................... 14 Fuel Limit Feature. ............................................................................ 15
CHAPTER 4: Operating and Tuning

Starting Engine for the First Time...................................................... 16 Gain................................................................................................... 16 Stability.............................................................................................. 16 Derivative. ......................................................................................... 16 Range Setting.................................................................................... 17 Fuel Limiting. ..................................................................................... 17 Saving Settings While Engine is Running. ........................................ 17
SDG700
SERIES
TABLE OF CONTENTS
CHAPTER 5: Specifications
Specifications. ...................................................................................18
CHAPTER 6: Troubleshooting
Engine Not Starting Checklist when not cranking ...........................19 Engine Not Starting Checklist when cranking ................................20 Bar Graph Flashing when power is applied to SDG ..........................21 Discrete Output Not Working: ............................................................21 Engine Not Running at correct Fixed Speed......................................21 Engine Not Running at correct Variable Speed .................................21 Overspeeding During Starting (Tripping Fault LED): .........................22 Overspeeding During Load Transient (Tripping Fault LED):..............22 Overspeeding During Speed Changes (Tripping Fault LED): ............22 SETUP MODE is not accessible........................................................22
SDG700
SERIES
INTRODUCTION
The SDG (Smart Digital Governor) is a solid state microprossor based device designed to control engine speed with fast and precise response to transient load changes. This closed loop control, when connected to an electric actuator and supplied with a magnetic speed sensor signal, will control a wide variety of engines in isochronous or droop mode. It is designed for high reliability and ruggedly built to withstand the harsh engine environment. Performance and affordability were foremost in the design. This powerful digital governor can be setup to meet your particular applications needs.
Integrated Heat sink Provides most efficient heat transfer enhancing performance.
Programming and Diagnostics Port Provides access to SDGs parameters for reprogramming, configuring or displaying.
Mode and Status Indicators provides real-time indications of key functions relative to run mode or setup mode.
Keypad for stand-alone configuration All parameters can be accessed through the keypad. No Laptop or other external device necessary for tuning and configuring. Keypad is resistant to petroleum products and water proof.
LED Bar Graph and Flash Code Display High intensity LEDs display all SDG settings.
Powder Coated Die Cast Aluminum Case Hard-potted providing a durable package to stand up against virtually any environment.
12 position Terminal strip Provides convenient method for installation. (7 position terminal strip is for additional features).
SDG700
SERIES
INSTALLATION
BATTERY 12V or 24V
S1
Fuse 15A Max
A B
GAIN STABILITY
DERIVATIVE
Actuator
C D E
10
Smart Digital Governor

REVD
9 8 7 6 5 4 3 2 1 0
Speed Trim / Variable Speed Magnetic Pick-Up + Bat. Speed Select Configurable Discrete Output
F G H I J K L
A C
Wiring Diagram FIGURE 1

The electrical connections are illustrated in Figure 1. For specific speed configuration using terminals J and K, please see Table 1 on the next page. Actuator and Battery connections to terminals A, B, C and D should be #14 AWG 2 (18mm ) or larger. Long cables require an increased wire size to minimize voltage drops. Battery positive (+) input, Terminal B should be fused for 15 Amps as illustrated. The Magnetic Speed Sensor connections to Terminals H and I MUST BE TWISTED AND/OR SHIELDED for their entire length. The speed sensor cable shield should be connected to Terminal A. The shield should be insulated to insure that no other part of it comes in contact with engine ground, otherwise, stray signals may be introduced into the SDG causing erratic operation.
5/10/01 Page 5 of 23
SDG700
SERIES
INSTALLATION
ACCESSORY WIRING The cables to the Speed (frequency) Trim Potentiometer can be of any reasonable length up to 5m (15ft). If over this length, a shielded cable is required. Connect the shield to Terminal A and to Case Ground as shown in Figure 1. Discrete Output for Controlling Fuel Stop Device The SDG72X series utilizes Terminal L for a discrete output that can be used to control a fuel stop device. The output is on when the SDG is powered and running in a normal condition. If Overspeed or some other programmed fault condition occurs then the Output will shut off. This output is designed as a current sink and is capable of sinking 20mA typically at 12Vdc through a 600-Ohm load. MAGNETIC PICKUP INSTALLATION With the engine stopped, adjust the gap between the magnetic speed pick-up and the ring gear tooth. The gap should not be any smaller than 0.45 mm (0.020 in.). Please follow the manufacturers instructions when installing. Verify proper installation by measuring the AC voltage output of the pickup while cranking the engine. The output should be a minimum of 0.5Vac
The Following table indicates how to select between Fixed Speed 1, Fixed Speed 2, Fixed Speed 3, and Variable Speed.
Terminals J No Connect No Connect + Battery + Battery K No Connect + Battery No Connect + Battery Selected Speed Variable Speed Fixed Speed 1 Fixed Speed 2 Fixed Speed 3 Selected Droop Droop Droop1 Droop2 Droop3
Table 1 Speed Select Settings
SDG700
SERIES
User Interface
F U N C T II O N M E N U FUNCT ON MENU
Once in SETUP MODE, the functions listed under each key can be accessed by using the MENU BUTTON. Each time the MENU BUTTON is pressed, the next menu will become active. Press until the desired menu is active Next press the particular key to access its function. For example press [menu] [menu] [5 key] to access Overspeed. The Bar Graph display will indicate which Menu is active.
1
GAIN Range
2
Stability
3
Derivative Fuel-Limit Menu 0 = LED0 ON Menu 1= LED1 ON Menu 2 = LED2 ON
6
Menu 0 = LED0 ON Menu 1= LED1 ON Menu 2 = LED2 ON
FixedSpd [RPM] Flywhl-Teeth Strt-Fuel-Ramp. Droop Overspeed [RPM] Strt-Fuel preset
7
Var-Spd-Hi-Lmt Var-Spd-Lo-Lmt Max Crank Term. MENU
9
Spd-Rampng-Acc. Spd-Rampng-Dec. Menu 0 = LED0 ON Menu 1= LED1 0N Menu 2 = LED2 ON
0
SETUP
ENTER RUN
Note: The fault light also comes on when a menu is active. This is useful if you are unsure if youve selected a menu.
SDG700
SERIES
USER INTERFACE
Bar Graph Display Mode
Bar Graph Mode displays the approximate percentage from 0 to 100%. By pressing the [+] or [-] arrow keys, increases or decreases the value. You may have to press the key several times to illuminate the next LED. This is due to the difference in resolution between the LEDs and the actual parameter being adjusted.
10 9 8 7 6 5 4 3 2 1 0
If only LED0 is on, this indicates the value is between 0% and 9%.
This Indicates the value is between 50% and 59%.
EXAMPLE 1 Bar Graph displaying between 50% and 59%. EXAMPLE 2 Code Flash Mode displaying the number 1500
Code Flash Mode

All SDG values that are flashed out are always 4 digits. The LEDs are labeled as 0, 1, 2,..,10. Code Flash Mode can display any value between 0 and 9999. They would be displayed by flashing 0-0-0-0 thru 9-9-9-9 respectively. Please review the example below of displaying the value 1500.
10 9 8 7 6 5 4 3 2 1 0 10 9 8 7 6 5 4 3 2 1 0 10 9 8 7 6 5 4 3 2 1 0 10 9 8 7 6 5 4 3 2 1 0 10 9 8 7 6 5 4 3 2 1 0 10 9 8 7 6 5 4 3 2 1 0
repeat
repeat
SDG700
SERIES
CONFIGURATION
Before starting the engine safely, The SDG must configured. This consists of: 1. Understanding the Keypad, Menus and Functions (Page 7). 2. Understanding the LED Display Modes (Page 8). 3. Entering SETUP MODE. 4. Configuring the necessary basic parameters. 5. Saving the new configured settings. Additionally, there is a group of Advanced Configurations that do not necessarily need to be preset for basic engine operation. These are listed below. (Their factory default states do not hamper basic operation.) 1. Staring Fuel Inhibitor control. (SFI is disabled per factory configuration.) 2. Speed Ramping for acceleration and deceleration rates. 3. Droop settings (All Droop settings are preset to 0%). The following group of functions are Advanced Features that may need to be preset before engine start. 1. Fuel Limit setup (Fuel Limit is disabled, indicated by Fuel Limit setting of 100%. ACCESSING SETUP MODE (a) Press and hold the [SETUP] key until RUN/SETUP LED begins to flash. (b) Now Enter the 4-digit security code followed by the [ENTER] key. [X], [X] , [X], [X], [ENTER] Note: Each time a key is pressed the Bar Graph LEDS will flash. (c) If the proper security code has been entered, the RANGE LEDs will begin flashing out the 4-digit Software version number. If not repeat step (b). (d) The RUN/SETUP LED will always be flashing while the SDG is in the SETUP mode. If you have problems during the configuration always check to make sure this LED is Flashing indicating you are in SETUP mode. (e) Pages 7 and 8 show how the display and menu features work on the SDG. You may need to refer to these periodically while configuring the SDG.
SDG700
SERIES
CONFIGURATION
FLYWHEEL TEETH
(NOTE: this is a critical setting because the SDG uses this setting to calculate Speed and Overspeed values. Please take extreme care when modifying this value) (a) Press the [MENU] button until Menu 0 is active. If necessary, refer to the FUNCTION MENU Selection found on page 7. (b) Now Press the [5] key to access Flywheel teeth mode. The RANGE indicator will flash out the present value of teeth. (c) Press the [+] or [-] keys to increase or decrease the number of flywheel teeth for your application. Note the Enter key is not pressed after adjustment using the [+] or [-] keys. (d) Proceed to the next step, Overspeed, if you are configuring the SDG for the first time. Otherwise, save and exit the setup routine by holding down the [RUN] button until the RUN/SETUP LED stops flashing. TIP: The value can be directly entered by using the keypad. All numeric keypad entries must contain 4 digits. For values of less than 4 digits enter zero(s) for the number of digits less than 4. Example: [0],[1],[0],[9],[ENTER], this sets the teeth to 109.
OVERSPEED
(NOTE: this is a critical setting because it is a necessary safety feature.) (a) Press the [MENU] button illuminating the FAULT LED and LED1. (b) Now Press the [5] key to select OVERSPEED mode. The Bar Graph LEDs will flash out the present RPM value of the OVERSPEED setting. This is based on the number of teeth entered. Therefore you must configure Overspeed every time you change Teeth. (c) Using the numeric keypad, enter the 4-digit RPM value of the desired OVERSPEED setting. If you make a mistake just re-enter the complete 4-digit number again. (d) PRESS the [ENTER] key to apply the 4-digit number just inputted. TIP: All numeric keypad entries must contain 4 digits. This means zeros must be entered even if only a 3-digit value is needed. Example: [0],[1],[0],[9],[ENTER], this sets the teeth to 109.
5/10/01 Page 10 of 23 REVD
SDG700
SERIES
CONFIGURATION
SPEED SETTINGS Connect the SPEED SELECT terminals J & K according to one of the four settings shown in Table 1 on page 6. If you have selected Variable Speed mode, then skip over Fixed Speed Operation to Variable Speed Operation below. FIXED SPEED OPERATION (a) Access Menu 0. (LED0 is on and Fault LED is on.) (b) Now Press the [4] key to access SPEED mode. The RANGE indicator will flash out the present RPM value of SPEED. (c) For small RPM change, use the [+] or [-] keys to increase or decrease the current RPM setting of the SPEED. (d) For large RPM change, use the Numeric keypad Entry method. (e) Re-configure the SPEED SELECT connections according to Table 1 to set up additional fixed speed settings and repeat steps (a) to (e) until all fixed speeds are configured. VARIABLE SPEED OPERATION (f) Make sure the potentiometer is attached as shown in Figure 1 on page 5. (g) Turn the Potentiometer such that maximum voltage is present on Terminal E. This can be verified by using the SDG Bar Graph Display in the next steps. (h) Access Menu 0. (LED0 is on and Fault LED is on.) (i) Press the [7] key to set the maximum RPM setting. This step also causes the SDG to remember the Potentiometers maximum position. At this point, the Bar Graph display also shows a representation of the voltage on Terminal E. If this reads zero then turn the pot to the other direction and repeat steps I and J. If the Bar Graph now reads higher then you must swap the wires at terminal F and G. Repeat steps h and i. (j) The present maximum RPM setting will be flashed out. (k) Use the [+] or [] keys or 4-digit keypad entry methods to set a new RPM value for the high limit. (l) Turn the Potentiometer such that minimum voltage is present on terminal E. (m) Access Menu 1. (LED1 is on and Fault LED is on.) (n) Press the [7] key to set the minimum RPM setting. This step also causes the SDG to remember the potentiometers minimum position. At this point the Bar Graph should be lower then the setting for max. position. (o) The present RPM setting will be flashed out. Use the [+] or [] keys or 4-digit keypad entry methods to enter new value for the RPM low limit.
5/10/01 Page 11 of 23 REVD
SDG700
SERIES
CONFIGURATION
CRANK TERMINATION SETTING This parameter must be set higher than the maximum cranking speed [RPM]. This helps the SDG to determine if the engine is cranking or running. Otherwise the SDG will invoke its Speed Control algorithms instead of its Starting Fuel algorithms during the starting cycle. When the SDG is in the RUN Mode (Verified by SETUP LED Steady), the LED labeled derivative is used as an indication telling you that the SDG is in the Start cycle. Once the engine is running the LED labeled Gain illuminates indicating the SDG is in the Engine Running Mode and is invoking the Speed Control algorithms. If you are attempting to start the engine and you notice the Gain LED lighting you may need to increase the Crank Termination Setting. (a) Access MENU 2. (Press and release the [MENU] button until Menu 2 is active.) (b) Now Press the [7] key to select Crank Speed Term. mode. The RANGE indicator will flash out the present RPM value. (c) Enter the desired RPM value as a four digit number. For example, 275RPM would be entered as [0],[2],[7],[5],[ENTER]. The Range indicator will flash out the new Crank Termination Setting.
SAVING SDG SETTINGS Press and Hold the [RUN] key until the RUN/SETUP LED stops blinking. This causes the SDG to save all settings into permanent memory. Without doing this all settings will be lost when the SDG is turned off. The SDG will now be in RUN mode verified by a steady RUN/SETUP LED.
5/10/01 Page 12 of 23 REVD
SDG700
SERIES
CONFIGURATION
STARTING FUEL INHIBIT CONTROL The parameter gradually increases the amount of fuel during the engine start cycle which eliminates unnecessary smoke. The higher the setting the more time it takes to reach full fuel (a) Enter Setup Mode (Accessing Setup Mode is found on Page 9). (b) Enter Starting Fuel Mode. (Press and Release the [MENU] button until MENU 0 is active then press the [6] key). (c) Use the [+] or [] keys to adjust the bar graph. Tip: The Engine should start more quickely as this value is decreased. Therefore a value of zero will not restrict any fuel. Tip: It may take several presses to see the LEDs change value. This is due to the fine-tune resolution between LED indicators. STARTING FUEL PRESET POINT Determines how much fuel to begin with before fuel ramping engages. (a) Insure you are in SETUP MODE. (b) Enter Starting Fuel Preset Mode. (Press and Release the MENU button until MENU1 is active then press the [6] key). (c) Use the + or keys to adjust the bar graph indicating what percentage of fuel the cranking cycle will begin with.
Fuel Maximum Fuel
Starting Fuel Inhibit set to 10%
Starting Fuel Inhibit set to 90% STARTING FUEL Preset POINT
Zero Fuel
Time [t]
Cranking Begins
Starting Fuel Diagram FIGURE 2 G o v e rr n o rr s A m e rr ii c a C o rr p .. Gove no s Ame ca Co p

5/10/01 Page 13 of 23 REVD
SDG700
SERIES
CONFIGURATION
SPEED RAMPING CONTROL Provides acceleration and deceleration ramping during RPM input changes. Acceleration Ramp: (a) Enter Speed Ramping Mode for Acceleration. (Press and release the [MENU] button until Menu 0 is active, followed by the [9] key). (b) Use the [+] or [] keys to set a new ramp rate. Tip: It may take several presses to see the LEDs change value. This is due to the fine-tune resolution between LED indicators.
Deceleration Ramp: (c) Enter Speed Ramping Mode for Deceleration. (Press and release the [MENU] button until Menu 1 is active followed by the [9] key). (d) Use the [+] or [] keys to set a new ramp rate.
DROOP SETTING Each of the four speed settings also have a corresponding droop setting. When the SDG ramps from Fixed Speed 1 to Fixed Speed2, the Droop value also ramps from Droop1 to Droop2. This type of operation provides maximum stability performance. (a) The Droop value is automatically selected based on which Speed is selected by terminals J and K (Table 1). (b) Enter DROOP Mode. Press and release the [MENU] button until Menu 1 is active followed by the [4] key. (c) Use the [+] or [] keys to select desired Droop amount in percent. SAVING SDG SETTINGS Press and Hold the [RUN] key until the RUN/SETUP LED stops blinking. This causes the SDG to save all settings into permanent memory. Without doing this, all settings will be lost when the SDG is turned off. The SDG will now be in the RUN mode indicated by the RUN/SETUP LED being steady.
5/10/01 Page 14 of 23 REVD
SDG700
SERIES
CONFIGURATION
FUEL LIMITING For preventing over fueling of the engine. If your Model is equipped for fuel Limiting, you will need to set the following parameter: Fuel-Limit setting This allows you to adjust the maximum amount of fuel the SDG will command. During the normal starting cycles and short step loads, this function will not engage. Only after a 1 second delay of the Fuel Limit exceeding its configured value, then the fuel will roll back to the configured value. This feature helps reduce excess smoke and helps prevent engine damage. FUEL LIMIT Sets the maximum fuel allowed after engine has started. (a) Enter Fuel-Limit Mode by enabling MENU 1 and then press the [3] key. (b) Use the keypad to adjust the Bar-Graph between 0 and 100% of the available fuel. Note: All LEDs on indicates no Fuel limiting enabled. All LEDs off indicates no fuel allowed and the engine will not start or run. A Bar Graph at 50% indicates Fuel will be limited to 50% of Maximum available fuel request.
5/10/01 Page 15 of 23 REVD
SDG700
SERIES
OPERATING AND TUNING

VERIFY SETTINGS Before starting the engine with the SDG connected please follow the steps listed below: 1. Apply power but do not start engine. 2. Enter Setup Mode (Page 9) and verify all settings are what you expect for: Flywheel Teeth, Overspeed, Speed configuration and Crank Termination. 3. Once you are satisfied press and hold the [RUN] button to exit Setup Mode. 4. Now you are ready to start the engine. STARTING ENGINE After engine has started use the Gain, Stability and Derivative (PID) parameters must be set for best performance. TUNING ENGINE (ADJUSTING PID) Gain adjustment. Press and release the [MENU] button until Menu 0 is active followed by the [1] key. The LED labeled Gain will illuminate and the bar Graph displays the percent setting of Gain. Use the [+] and [] buttons to increase or decrease the gain. Note: if you the [+] or [-] button is held, it will change the value rapidly. When done setting the gain parameter do not press the [ENTER] key. This will apply an erroneous value to the gain setting and cause unstable engine performance. If the [ENTER] key is pressed, just [+] and [] keys to reset the gain value. Stability adjustment. Press and release the [MENU] button until Menu 0 is active followed by the [2] key. The LED labeled Stability will illuminate and the Bar Graph displays the percent setting of Stability. Use the [+] and [] buttons to increase or decrease the Stability. Note: if you press and hold the button it will allow you to rapidly change the value. When done setting the Stability parameter, do not press the [ENTER] key. This will apply an erroneous value to the Stability setting and cause unstable engine performance. If you do then just use the [+] and [] keys to reset the Stability value. Derivative adjustment. Press and release the [MENU] button until Menu 0 is
5/10/01 Page 16 of 23 REVD
SDG700
SERIES
OPERATING AND TUNING

active followed by the [3] key. The LED labeled Derivative will illuminate and the Bar Graph displays the percent setting of Derivative. Use the [+] and [] buttons to increase or decrease the Derivative. Note: if you press and hold the button it will allow you to rapidly change the value. When done setting the Derivative parameter, do not press the [ENTER] key. This will apply an erroneous value to the Derivative setting and cause unstable engine performance. If the [ENTER] key is pressed, just use the [+] and [] keys to reset the Derivative value. RANGE SETTING This function will double or triple the Gain and Stability parameter ranges but reduces resolution. This is useful when large amounts of gain and stability are needed. This function basically multiplies the Gain and Stability parameters by 1,2, or 3. The normal setting for the Range is 1. By changing it to 2 or 3, the values are doubled or tripled. To access Range adjustment press and release the [MENU] button until Menu 2 is active followed by the [1] key. The number is flashed out as either 0,0,0,1 or 0,0,0,2 or 0,0,0,3. Use the [+] and [] buttons to adjust. SETTING FUEL LIMIT FEATURE This feature is useful in limiting excess smoke and reducing possible engine damage due to overload conditions. While the engine is running at specified load, gradually decrease the Fuel Limit setting. Remember there is a 1 second delay before it actually engages therefore it is important to adjust very slowly. When the engine speed begins dropping off, increase the Fuel Limit until the engine regains normal speed. This function incorporates a 1 second delay. This is to prevent it affecting the engine start cycle and step loads. When the SDG is in the RUN Mode, the LED labeled derivative will illuminate when Fuel Limiting is active. Press and release the [MENU] button until Menu 1 is active followed by the [3] key SAVING VALUES (While Engine is Running) When all tuning and engine configuration is complete, press and hold the [RUN] button to save all settings. You may notice a slight engine stutter when saving the settings. This is normal and only occurs during the saving process.
5/10/01 Page 17 of 23 REVD
SDG700
SERIES
SPECIFICATIONS
PERFORMANCE
Isochronous Operation/Steady State Stability -------------------------------0.25% or better Speed Range/Governor------------------------------------------------------------400 10KHz Speed Drift with Temperature ----------------------------------------------------TBD% Maximum Idle Adjust------------------------------------------------------------------------------Full Range of set speed Droop Range--------------------------------------------------------------------------1 17% Regulation Speed Trim Range ------------------------------------------------------------------5% of Running Speed.
ENVIROMENTAL
Ambient Operating Temperature Range ---------------------------------------40o to 85oC(-40 to +180F) Relative Humidity --------------------------------------------------------------------Up to 95% All Surface Finishes -----------------------------------------------------------------Fungus Proof and Corrosion Resistant
INPUT / OUTPUT PARAMETERS

Supply ----------------------------------------------------------------------------------12 or 24Vdc Battery Systems (6.5Vdc to 33Vdc) Polarity----------------------------------------------------------------------------------Negative Ground (Case Isolated) Power Consumption ----------------------------------------------------------------70mA max. continuous plus actuator current Actuator Current Range @ 25oC (77F) (Inductive Load) --------------Min. 2.5Amps, Max. 10 Amps continuous Speed Sensor Signal ---------------------------------------------------------------0.5-120 Volts RMS Load Sharing and Synchronizing Input ----------------------------------------0 - 10Vdc (Protected against Shorts to battery + & -) Discrete Output-----------------------------------------------------------------------Supply up to 25mA, Rated 20mA@12V 600 Ohms
CONFIGURATION PARAMETERS
Flywheel Teeth -----------------------------------------------------------------------50 150 (Can be extended) Range (Gain and Stability Multiplier) ------------------------------------------1,2,3 Fixed Speed settings ---------------------------------------------------------------0-Max RPM* Variable Speed settings------------------------------------------------------------0-Max RPM* Overspeed Setting-------------------------------------------------------------------0-Max RPM* Starting Fuel Preset -----------------------------------------------------------------0-Max Fuel
RELIABILITY
Vibration--------------------------------------------------------------------------------7G@20-100Hz. Testing----------------------------------------------------------------------------------(100%) Functionally Tested
PHYSICAL
Dimensions----------------------------------------------------------------------------9.6cm x 14.1cm x 3.7cm (3.765 x 5.55 x 1.44 inches) Weight ----------------------------------------------------------------------------------0.64kg (1.41lbs) Mounting -------------------------------------------------------------------------------Direct Engine Mounting, vertical preferred
*Note: Max RPM is based on the Flywheel Teeth. RPM=Frequency*60/FlywheelTeeth. Maximum frequency is 10,000 Hz.
5/10/01 Page 18 of 23 REVD
SDG700
SERIES
TROUBLESHOOTING GUIDE
Engine Will Not Start - Checklist when after you stop cranking
Indicates the Overspeed limit was exceeded during starting. Recheck Flywheel Teeth, Overspeed, and Speed settings. Cycling the power on the SDG will remove the Overspeed Fault Condition. Try Restarting. SDG is in SETUP Mode. Press and hold the RUN Button to exit Setup Mode and enter RUN Mode. The Fault LED should turn off. If is doesnt that means the Overspeed limit was exceeded during starting. Recheck Flywheel Teeth, Overspeed, and Speed settings. Cycling the power on the SDG will remove the Overspeed Fault Condition. Try Restarting.
Y With Power applied to SDG, Is Fault LED on?
Is RUN/SETUP LED Blinking
Is RUN/SETUP Y LED Blinking
N Are any LEDs on Y
Is the battery (+) connected to terminal B and Battery (-) connected to terminal A? Verify polarity.
Is RUN/ SETUP LED N steady On Y
Connect Battery
Measure Voltage across Terminals A(-) and B(+) to verify sufficient Voltage (12V or 24V). Cycle Power. If Still no LEDs turn on, then controller needs to be replaced.
Go To Next Section Labeled WHILE CRANKING the ENGINE
5/10/01 Page 19 of 23 REVD
SDG700
SERIES
Engine Will Not Start- Checklist while cranking the Engine
Measure Voltage across Terminals A(-) and B(+) while engine is cranking. Verify sufficient Voltage of approx. 8V. If not then make sure the battery is charged.
When Cranking Engine, N Are any SDG LEDs on Y Y
Is the Gain LED Turning on?
This indicates either the Crank Termination or the Fuel Limit Setting is too low. Typically the Crank Termination value should be at least 50RPM higher than the max. cranking speed of the engine. If possible measure the cranking RPM of the engine. Enter Setup Mode and configure the Crank Termination Setting [MENU][MENU][MENU][7] to a higher value. You can try 100 RPM increments. If Engine appears to start and the Stability LED illuminates, this indicates the Fuel Limit Setting may be too low. Enter the Fuel Limit Function {SETUP MODE} then [MENU][MENU][3]. The Bar Graph displays the Fuel Limit setting. Use the [+] key to set it to 100% which disables it. If neither the Derivative nor the Gain LEDs are turning during cranking, this indicates the SDG is not seeing the pickup signal. Verify the pickup sensor is connected to terminals H and I. If possible measure the pickup signal while the engine is cranking. The voltage must be a minimum of 0.5VRMS for proper operation. This indicates the Starting Fuel Function is engaged. This can be remedied by entering the Starting Fuel Inhibit Function and setting the fuel ramp to 0000. Enter Setup Mode and access the Starting Fuel Function [Menu][6]. Next enter [0][0][0][0][ENTER]. This enters zero into the Staring Fuel Inhibit Control Ramp. This is verified by the Bar Graph displaying 0%.
Is the Derivative LED Turning on?
Y
Does the Bar Graph Display show more than 0% while cranking?
This indicates the SDG is seeing the Pickup Sensor and is invoking the Starting Algorithm. Make sure the actuator is connected to Terminals C and D. Measure the voltage across these terminals while the engine is cranking. This voltage should be at no less than 2Vdc lower than supplied Battery Voltage during cranking. Other things to check are the settings for Flywheel Teeth, Speed Setting(Fixed or Variable), Another possibility for not starting may be due to an extremely long fuel ramp. This can be disabled by Entering Setup Mode and accessing the Starting Fuel Function [Menu][6]. Next enter [0][0][0][0][ENTER]. This enters zero into the Staring Fuel Inhibit Control Ramp. This is verified by the Bar Graph displaying 0%.
5/10/01 Page 20 of 23 REVD
SDG700
SERIES
Bar Graph Flashing when power is applied to SDG: This indicates the SDG configuration is corrupt. It Is recommended to reconfigure the unit before attempting to start the engine. Discrete Output Not Working: This terminal sinks current. The typical amount of sink current is 20mA. This means the device being controlled with this pin must be tied to a positive voltage and must not require more than 20mA to operate. This pin turns on when the SDG is running under normal conditions. If the SDG Overspeeds then this pin switches to an open circuit. Engine Not Running at correct Fixed Speed. Are terminals J and K properly configured? If nothing is connected to these terminal the SDG is configured for Variable Speed. Please refer to TABLE 1 in the installation section of this manual for more information. Make sure the correct number of flywheel teeth have been configured. This function is accessed in the Setup Mode then entering [MENU][5]. The SDG will flash out the current number of teeth as a 4-digit code. If this number is not correct then enter the correct number of teeth as a 4digit number followed by the [ENTER] button. Make sure the Fixed Speed is correctly set. Access Setup Mode and select Fixed Speed Setting [MENU][4]. This Flashes out the present RPM speed. If this is not correct, enter the 4 digit speed in RPM and press [ENTER]. The SDG will Code Flash the proper RPM Speed. Note: The maximum RPM speed is based on the number of teeth selected. Typically the maximum RPM speed is 5000-6000RPM. Engine Not Running at correct Variable Speed. Make sure potentiometer is connected properly to terminals E, F, and G. Refer to the configuration section this manual to setup the for the potentiometer. When configuring the potentiometer. Verify the RPM value entered for MAX. RPM SPD [MENU][7] is greater than the RPM entered for MIN. RPM SPD [MENU][MENU]7. When doing this also verify the Bar Graph displays a higher reading for MAX. RPM SPD
5/10/01 Page 21 of 23 REVD
SDG700
SERIES
when selecting than for MIN. RPM SPD. Note each time one of these functions are selected, A 4 digit RPM value must be entered. Make sure the correct number of flywheel have been configured. This function is accessed in the Setup Mode then entering [MENU][5]. The SDG will flash out the current number of teeth as a 4-digit code. If this number is not correct then enter the correct number of teeth as a 4-digit number followed by the [ENTER] button. Overspeed During Starting (Tripping Fault LED): This is caused by having the Overspeed setting too low, SDG not properly tuned for the application or the Crank Termination Setting too high. Recheck these parameters. Overspeeding During Load Transient (Tripping Fault LED): Overspeed setting too low or SDG not properly tuned for the application. Recheck the Overspeed setting and try retuning the engine. Overspeeding During Speed Changes (Tripping Fault LED): Overspeed setting too low or the Speed Ramp Acceleration set too low. By increasing the Speed Ramp Value in Setup Mode and then pressing [MENU][9], this shows the bar graph of the Speed Ramp. Press the [+] button to increase this value. This causes the engine to accelerate more slowly reducing the overshoot. SETUP MODE is not accessible: Press and hold the [SETUP] until the RUN/LED lamp starts to flash. Now you must enter the valid 4-digit security code [1][2][3][4] followed by the [ENTER] button. Each unit has a specific security code. If you forgot the code you must contact your distributor from where the SDG was purchased. Note: Once youve entered the proper code the SDG will flash of the Software Version Number.
5/10/01 Page 22 of 23 REVD
SDG700
NOTES:
SERIES
5/10/01 Page 23 of 23 REVD

Manual SDG725

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Manual SDG725

Uploaded by

Copyright:

Available Formats

SDG700

Smarrtt Sma Diigiittall Dg a Goverrnorr Gove no

CHAPTER 2: User Interface

CHAPTER 3: Configuring SDG

CHAPTER 4: Operating and Tuning

BATTERY 12V or 24V

Fuse 15A Max

Smart Digital Governor

Wiring Diagram FIGURE 1

Table 1 Speed Select Settings

FixedSpd [RPM] Flywhl-Teeth Strt-Fuel-Ramp. Droop Overspeed [RPM] Strt-Fuel preset

This Indicates the value is between 50% and 59%.

Code Flash Mode

Fuel Maximum Fuel

Starting Fuel Inhibit set to 10%

Starting Fuel Inhibit set to 90% STARTING FUEL Preset POINT

Starting Fuel Diagram FIGURE 2 G o v e rr n o rr s A m e rr ii c a C o rr p .. Gove no s Ame ca Co p

OPERATING AND TUNING

OPERATING AND TUNING

INPUT / OUTPUT PARAMETERS

Y With Power applied to SDG, Is Fault LED on?

Is RUN/SETUP LED Blinking

Is RUN/SETUP Y LED Blinking

N Are any LEDs on Y

Is RUN/ SETUP LED N steady On Y

Go To Next Section Labeled WHILE CRANKING the ENGINE

When Cranking Engine, N Are any SDG LEDs on Y Y

Is the Gain LED Turning on?

Is the Derivative LED Turning on?

You might also like