Initial Checks & Adjustments At Installation

Introduction

This section is a guide to be used for first installation of the engine or when a replacement of any of the equipment has been made. Too often the equipment is damaged or destroyed before it ever has a chance to be used because of incorrect wiring, lead shorts, wrong polarity, a mechanical problem, or overvoltage.

The information that follows contains a basic, step by step checklist to be followed. Before any supply power is applied, all wiring and settings are verified to be correct, as well as the correct voltage level. Then the governor is energized and the components are checked out to see if they function correctly. Finally the engine is started, and the complete system is checked and adjusted dynamically.

The correct use of these initial checks will eliminate most of the early failures that can occur.

Static Checks

Visual Inspection

At Engine

1. Governor linkage checks:

a. Linkage moves freely, not binding.

b. Correct thread engagement of rod ends.

c. Full travel available to Fuel Off position.

d. Full travel available to Fuel On position.

2. Magnetic pickup to flywheel ring gear tooth clearance ... 0.5 to 0.8 mm (.02 to .03 in)

3. Magnetic pickup resistance ... approximately 200 ohms

4. Shielded wire checks:

a. Only governor end to be connected to terminals indicated on Governor Connection Diagram.

b. Not in same conduit with high current cables.

Power Supply Check

It is recommended to use a battery with a charger (60A hour battery rating or larger), or a separate DC power supply (8A or larger).

The following tests are performed to verify that the power supply is in the correct voltage range, is clean (no alternating current), and is of sufficient amperage (little or no voltage drop).

KG30 Governor Control Unit
(1) 14 Pin receptacle. (2) 2 Pin receptacle (magnetic pickup). (3) 10 Pin receptacle (accessory connection).

1. Before turning on the power to the KG30 governor control unit, disconnect the large 14 pin plug from the 14 pin receptacle (1) and connect a multimeter in the DC volts mode to this plug in the wiring harness at pin E (+) and pin F (-). Turn on power to the KG30 governor control unit. The voltage must be 20 to 35V DC (preferably 24V DC). With the multimeter still connected, put the multimeter in AC volts mode. If it reads more than approximately 1V AC, the voltage supply must be inspected to find the source of the excessive AC voltage. Do not connect the plug to the controller if any excessive AC voltage is present. The governor system will not function properly, and it can be damaged.

2. Once the voltage is verified to be clean and in the correct range from the previous test, connect the main 14 pin connector to the KG30 governor control unit and disconnect the magnetic speed pickup connector (2) and accessory connector (3).

KG30 Governor Control Unit
(4) 10 pin switch.

3. Take the 10 pin switch (4) which comes with governor test unit and put "MOT-STOP" switch in the "MOT" position. Put "P-I" switch in the "I" position. Insert the 10 pin switch in the 10 pin receptacle (3) on the KG30 governor control unit.

KG30 Governor Control Unit
(5) Diode (+). (6) OV (-). (7) TP6 (+).

4. Connect the multimeter in DC volts mode to OV (-) (6) and to the diode (+) (5). Turn on power supply and record this static voltage at the KG30 governor control unit. It should be 20 to 35V DC.

5. Connect governor test unit according to instructions, put switch in position 3 and turn on governor test unit. Adjust load potentiometer on governor test unit until actuator pointer is at 40 to 60%. Refer to Special Instruction, Form No. SEHS9222 for use of this tool group.

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With the governor test unit turned on the actuator and linkage will move which could result in personal injury.

6. Put "MOT-STOP" switch in "STOP" position to drive actuator to shutoff and record this voltage. As an alternative to using the "MOT-STOP" switch in the "STOP" position, jumper across terminals H3 and I3 in the 10 pin receptacle (3) on the KG30 governor control unit. This will also drive the actuator to shutoff.

With the actuator at shutoff, this is the minimum voltage the control will see since it is at the maximum current draw of the actuator. This minimum voltage (voltage drop) must be a maximum of 2 volts less than the static control voltage recorded earlier.

If the voltage drop is less than 2 volts (preferable less than 1 volt) the power supply and power cables are acceptable.

If the voltage drop is more than 2 volts, the control is not getting sufficient amperage from the power supply for one of two reasons. The power supply is less than the required amperage or there is a voltage drop due to high resistance in the supply cables from the power source to the KG30 governor control unit.

7. To determine the fault, connect the DC voltmeter to the source of the DC power (battery or DC power supply. Rerun the previous test with the governor test unit to determine voltage drop at the power source.

If the voltage drop is now less than 2 volts there is a high resistance in the power cables to the KG30 governor control unit. Check all connections for resistance and the Governor Connection Diagram for proper wire sizes.

If the voltage drop at the power source is more than 2 volts, the battery or DC power supply has insufficient amperage and must be increased in size. Do not run engine until maximum voltage drop at the KG30 governor control unit is 2 volts or less.

8. When finished with the previous tests, turn off power to KG30 governor control unit and disconnect multimeter and governor test unit.

Initial Adjustments (Static)

Actuator:

No actuator adjustments are necessary or possible, and none should be attempted.

KG30 Governor Control Unit:

Remove the cover from the KG30 Governor Control Unit and:

KG30 Governor Control Unit
(1) Gain potentiometer. (2) Stability potentiometer. (3) Derivative potentiometer. (4) Gas-Diesel switch. (5) Fast response potentiometer. (6) Damping potentiometer.

1. Set gain potentiometer (1) to 30%.

2. Set stability (2) to 30%.

3. Set derivative (3) to 0%.

4. Set "Gas-Diesel" switch (4) to "Diesel".

5. Set fast response (5) and damping (6) potentiometers fully counterclockwise (CCW).

Wiring Schematics

Power Supply Connection (Customer Supplied)
(1) Charger (if battery used). (2) Battery or power supply (20 to 35 VDC). (3) Fuse (15A). (4) Wire (to governor). (5) Governor on/off switch (20A).

NOTE: Always connect power cables directly to battery (or power supply) with fuse and switch in positive line.

Correct Shielding Of Cables

To insure reliable operation of the governor system, all signal carrying wires must be shielded as shown on the Governor Connection Diagram. Incorrect shielding can cause unstable engine operation and can cause damage to the governor components over a period of time if not corrected. The shield must be connected at one end only; the other end must not be connected and must not have any connection to ground or to the negative (-) battery terminal.

When a shielded cable is wired through a terminal strip, the shield must also be connected through the terminal strip without contact to the negative (-) side of the battery or ground.

Correct Shield Connection

Incorrect Shield Connection

Right and left shield connected to different ground terminals.

Incorrect Shield Connection

Shield is broken at terminal strip.

Incorrect Shield Connection

Shield is additionally connected to the battery ground (-).

Governor Connection Diagram [L1 & L2 ... to 20 m (65.6 ft)]

(1) Droop potentiometer, 500 KOhms.

(2) Droop switch.

(3) Isochronous mode.

(4) Droop mode.

NOTE: Callouts 1, 2, 3 and 4 only used when it is required to externally switch between droop and isochronous modes.

(5) Remote speed set point potentiometer, 5 KOhms.

(6) Synchronizer.

(7) Load sharing (equal fuel).

(8) Load anticipation.

(9) Load sharing (kilowatt).

(10) Engine stop switch.

(11) Magnetic pickup.

(12) Gap between pickup and flywheel ... 0.5 to 0.8 mm (.02 to .03 in)

Cable Size:

L1 (governor control unit to battery):

Up to 7 m (23 ft) ... 2 × 1.5 mm² (14 AWG)

7 to 12 m (23 to 39 ft) ... 2 × 2.5 mm² (12 AWG)

12 to 20 m (39 to 65.6 ft) ... 2 × 4 mm² (10 AWG)

L2 [governor control unit to actuator, up to 20 m (65.6 ft)]:

Cable I ... 2 × 2.5 mm² (12 AWG)

Cable II (with shielded cable) ... 3 × 0.75 mm² (18 AWG)

L3 (governor control unit to set point potentiometer-with shielded cable)

3 × 0.75 mm² (18 AWG)

L4 (governor control unit to magnetic pickup-with shielded cable)

2 × 0.75 mm² (18 AWG)

L5 (governor control unit to accessory unit-with shielded cable)

1 mm² (16 AWG)

Checking The Shield (Screen)

Terminals D, F, G, K, B2, A3, AND H3 are all a common connection inside the KG30 governor control unit. When all connections are made these terminals are all common (-) to the battery through the F terminal connection.

KG30 Governor Control Unit
(1) 14 Pin receptacle. (2) 2 Pin receptacle (magnetic pickup). (3) 10 Pin receptacle (accessory connection).

With power off to the KG30 Governor Control Unit:

(A) Check for undesired shield connections:

1. Disconnect plug from the 14 pin receptacle (1).

2. Check D & K terminals in plug against battery ground (-). Ohmmeter should read open circuit or infinite ohms.

3. Disconnect plug from the 2 pin receptacle (2).

4. Check B2 terminal in plug to battery ground (-). Ohmmeter should read open circuit or infinite ohms.

5. Disconnect plug from the 10 pin receptacle (3).

6. Check A3 & H3 terminals in plug to battery ground (-). Ohmmeter should read open circuit or infinite ohms.

NOTE: Purpose of the above tests is to insure that shields are not tied to ground at a second point in the harness (cable) assembly. If they are it is necessary to find unwanted connection and remove it.

(B) Check for desired shield connections:

With all plugs (control harnesses) still disconnected from the governor control unit check the following.

1. Check continuity with ohmmeter between end of cable shield and terminal in plug. To check end of cable shield, pierce outer cable insulation with needle type ohmmeter probe to contact shield. Ohmmeter should read 0 ohms. Specific checks are:

a. L2 (governor control unit to actuator) between shield at actuator end of cable and K terminal in plug.

b. L3 (governor control unit to set point potentiometer) between shield at potentiometer end of cable and D terminal in plug.

c. L4 (governor control unit to magnetic pickup) between shield at magnetic pickup end of cable and B2 terminal in plug.

d. L5 (governor control unit to accessory unit) between shield at accessory connection and A3 terminal in plug. A variation of this may exist with the use of some accessories as shown on their wiring diagrams.

e. L5 (governor control unit to engine stop switch) between shield at engine stop switch (if switch is used) and H3 terminal in plug.

NOTE: An ohmmeter reading of infinity (open circuit) during any of the above tests in "Procedure B" indicates incorrect shielding and this must be corrected before operating engine.

Static Checks/Adjustments

The following checks and/or adjustments are made statically before the engine is started:

1. Actuator Feedback Voltage

2. Rated Speed

3. Idle Speed

4. Droop

5. Start Fuel Limit

To make these adjustments turn off power to governor control unit, connect 14 pin plug of the wiring harness to the KG30 governor control unit and the 5 pin plug of the wiring harness to the actuator, disconnect magnetic pickup cable (L4) and accessory cable (if used) at the governor control unit, connect governor test unit according to instructions. Refer to Special Instruction, Form Number SEHS9222, for use of this tool group.

1. Actuator Feedback Voltage

StG30 Actuator (With Base)
(1) Position indicator plate. (2) Connector (from governor control unit). (3) Actuator output shaft. (4) Position indicator.

KG30 Governor Control Unit
(5) Stop 1.5V potentiometer. (6) Max speed potentiometer. (7) Droop potentiometer. (8) Max Fuel 5V potentiometer. (9) Min speed potentiometer. (10) Droop-Isoch switch.

Put governor test unit in position 2 (feedback) and disconnect linkage on actuator. Turn on power to governor control unit and turn on governor test unit. With the actuator output shaft (3) at the 0% position on position indicator plate (1) the feedback voltage should read 1.5 ± .1V DC. Adjust potentiometer marked Stop 1.5V (5) if needed. Now hold actuator output shaft (3) in 100% position. The feedback voltage should read 5.0 ± .1V DC. Adjust potentiometer marked Max Fuel 5V (8) if needed.

Remember, the governor test unit in position 2 (feedback) reads in millivolts, not volts.

2. Rated Speed

KG30 Governor Control Unit
(5) Stop 1.5V potentiometer. (6) Max speed potentiometer. (7) Droop potentiometer. (8) Max Fuel 5V potentiometer. (9) Min speed potentiometer. (10) Droop-Isoch switch.

With power to governor control unit off, connect linkage to actuator. Put governor test unit in position 3 (engine simulation) and put load potentiometer on governor test unit in 12 o'clock position. Turn remote speed set point potentiometer to maximum speed (fully clockwise [CW]). Put Droop-Isoch switch (10) in isochronous position (right position). For droop operation read this entire section (Step 2. Rated Speed) and then go to Step 4, Droop Adjustment. Turn on governor test unit, power to governor control unit and read frequency in Hertz. If at any point the governor test unit's digital display reads zero, turn off governor test unit and turn on again, or turn load potentiometer fully counterclockwise (CCW) for several seconds to reset governor test unit. Also verify governor test unit has a good battery.

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With the governor test unit turned on the actuator and linkage will move which could result in personal injury.

Adjust potentiometer marked max (6) until the governor test unit reads approximately 2% above desired rated frequency. Always adjust rated speed before adjusting idle speed.

NOTE: Use the following formula to convert rpm to Hertz (Hz):

For 3600 engines with a standard 255 tooth flywheel use the following chart:

Remember, the governor test unit reads in Hertz.

3. Idle Speed

KG30 Governor Control Unit
(5) Stop 1.5V potentiometer. (6) Max speed potentiometer. (7) Droop potentiometer. (8) Max Fuel 5V potentiometer. (9) Min speed potentiometer. (10) Droop-Isoch switch.

With the governor test unit still set from Step 2, turn the remote speed set point potentiometer to minimum speed (fully counterclockwise [CCW]). Adjust potentiometer marked min (9) until desired idle frequency is attained. Once idle and rated speeds are set, move the remote speed set point potentiometer from minimum to maximum several times to confirm idle and maximum speeds are correct.

NOTE: Turn the load potentiometer on the governor test unit clockwise (CW) and counterclockwise (CCW) several times to move the fuel system linkage to verify all connections are correct and that there is no binding or sticky spots in the linkage.

4. Droop Adjustment

KG30 Governor Control Unit
(5) Stop 1.5V potentiometer. (6) Max speed potentiometer. (7) Droop potentiometer. (8) Max Fuel 5V potentiometer. (9) Min speed potentiometer. (10) Droop-Isoch switch.

NOTE: On applications where the LMG 03 Loadshare Unit is used with the KG30 Control Unit and it is desired to run in droop, the KG30 is put in the "Isochronous" mode (right-most switch position) and the droop is adjusted in the LMG 03.

If it is desired to run in droop, put Droop-Isoch switch (10) in droop position (left most position). Set droop potentiometer (7) to the 80% position as a starting point. With the remote speed set point potentiometer in the maximum position (fully clockwise [CW]), adjust the load potentiometer on the governor test unit until the actuator opens to the same position (same mm of rack) as rated load at rated speed. Adjust max speed potentiometer (6) until about 2% above rated speed is reached. Turn the load potentiometer on the governor test unit until the rated speed - no load fuel position is reached. The frequency on the governor test unit will increase. The frequency should be about 2% above no load rated speed. If the no load frequency is too high turn the droop potentiometer (7) CCW 10% and recheck frequencies. Turn the droop potentiometer CW if the no load frequency is too low. Adjust max speed potentiometer (6) and droop potentiometer (7) following this method until the desired speeds are attained. The droop may have to be fine tuned on the running engine. Go to Step 3 to set Idle Speed.

5. Start Fuel Limit Adjustment

KG30 Governor Control Unit
(1) Diode. (2) Start fuel limit potentiometer. (3) OV (-). (4) TP6 (+). (5) Start fuel limit slide switch. (6) Green LED light.

NOTE: For applications not requiring start fuel limiting, the Start Fuel Limit function can be eliminated by placing the start fuel limit slide switch (5) in position 2 or 3, or by turning the start fuel limit potentiometer (2) fully clockwise (CW).

1. With power to governor control unit turned off, turn Start Fuel Limit potentiometer (2) counterclockwise (CCW) until a "clicking" noise is heard (end point of potentiometer). Now turn potentiometer 10 turns clockwise (CW) as a starting point. Put start fuel limit slide switch (5) in position 4 (start fuel limiting position).

2. Install a 8T1000 Electronic Position Indicator. Refer to Special Instruction, Form Number SEHS8623, for use of this tool group.

KG30 Governor Control Unit
(1) Diode. (2) Start fuel limit potentiometer. (3) OV (-). (4) TP6 (+). (5) Start fuel limit slide switch. (6) Green LED light.

3. As an aid in adjustment, connect the multimeter (0 to 5V DC range) to TP6 (4) and OV (3) to measure actuator feedback voltage (actuator position). Turn power on to governor control unit. Manually move the rack to the desired start fuel limit position by reading the 8T1000 Electronic Position Indicator. Record the actuator feedback voltage at this position. From this point on, use the actuator feedback voltage as an indicator of rack position.

4. If the KG30 Governor Control Unit has a serial number of 90-02-1499-30 or higher, go to Step 5. If the serial number is less than 90-02-1499-30, go to Step 6.

KG30 Governor Control Unit
(7) 14 Pin receptacle. (8) 2 Pin receptacle (magnetic pickup). (9) 10 Pin receptacle (accessory connection).

5. Put a jumper wire between terminals H3 and J3 of the 10 pin receptacle (9) of the KG30 Governor Control Unit. This will defeat the speed pickup failsafe and the actuator will move the engine rack to the start fuel limit position. Turn the start fuel limit potentiometer (2) until the desired limiting position, determined in Step 3, is reached. Clockwise (CW) rotation of the potentiometer increases fuel on startup. Remove the jumper wire from terminals H3 and J3 and go to step 8.

6. With the governor test unit turned off and connected from previous steps, put selector switch on governor test unit in position 3, turn load potentiometer on governor test unit to the 8 o'clock position. Turn on governor test unit and slowly turn load potentiometer clockwise (CW). The actuator will slowly open, stop at a limiting position for a moment, and then go to shutoff. Record the actuator feedback voltage at the limiting position. If the digital display on the governor test unit reads zero, turn load potentiometer fully counterclockwise (CCW) for several seconds to reset.

NOTE: The green LED light (6) that indicates fuel limit is working must be on during all steps.

7. Adjust the actuator feedback voltage from the limiting position of Step 6 until it is the same as the desired feedback voltage recorded in Step 3. Turn the start fuel limit potentiometer (2) clockwise (CW) to increase fuel on startup, counterclockwise (CCW) to decrease fuel on startup.

8. As a guide, one complete turn clockwise (CW) of the start fuel limit potentiometer (2) increases the actuator feedback voltage at the start fuel limit position approximately 0.2 volts (6% actuator angle).

9. The start fuel limit is turned off automatically when the set point speed is reached and is reset for the next start.

Turn off power to KG30 governor control unit. Disconnect governor test unit and multimeter. Reinstall magnetic pickup cable and accessory cable (if used) to the KG30 Governor Control Unit and install cover.

Energized Governor Checks (Static)

KG30 Governor Control Unit
(1) Red LED light. (2) Start fuel limit slide switch. (3) Green LED light.

When 20 to 35V DC is applied to the governor control unit and all cables are connected correctly the red LED (1) marked control lamp will light. This light will go out when the magnetic pickup frequency is greater than 150 Hz (or when the governor test unit is used). Also, if the start fuel limit slide switch (2) is in position 4 (fuel limiting) it's green LED light (3) will be on when the engine is static or below set point speed.

Dynamic Checks

Initial Engine Operation

1. Make sure all Static Checks are completed before Dynamic Checks are started.

2. Turn on power to governor control unit.

3. Set remote speed set point potentiometer to minimum (idle) position.

KG30 Governor Control Unit
(1) Gain potentiometer. (2) Stability potentiometer. (3) Derivative potentiometer. (4) Start fuel limit potentiometer.

4. Remove cover from KG30 Governor Control Unit. Be prepared to adjust gain (1) or stability (2) potentiometers if the engine is unstable.

5. Start Engine. If the engine will not start, but the actuator does rotate slightly, turn the start fuel limit potentiometer (4) in 1/2 turn increments clockwise (CW) until the engine starts easily. If the engine starts easily but with excessive smoke, turn the start fuel limit potentiometer (4) counterclockwise (CCW) in 1/2 turn increments until the smoke is acceptable.

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The engine must not be started when either the governor test unit or a frequency generator is connected to the KG30 Governor Control Unit. This could result in engine overspeed or personal injury.

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NOTICE
Be ready to control the engine shutoff manually if there is no oil pressure, or if oil pressure is too low. Damage to the engine will be the result if the engine continues to run without the correct oil pressure.

6. Bring engine up to rated speed by slowly turning remote speed set point potentiometer clockwise (CW). If the engine is stable follow "Procedure A". If the engine is unstable follow "Procedure B". After completing A or B go to "Procedure C".

A. If the engine is stable (less than 10 rpm peak-to-peak speed fluctuation), optimize the dynamic settings as follows:

KG30 Governor Control Unit
(1) Gain potentiometer. (2) Stability potentiometer. (3) Derivative potentiometer. (4) Start fuel limit potentiometer.

a. Turn stability potentiometer (2) fully counterclockwise (CCW).

b. Slowly turn gain potentiometer (1) clockwise (CW) until unstable, then counterclockwise (CCW) until stable.

c. Slowly turn stability potentiometer (2) clockwise (CW) until unstable, then counterclockwise (CCW) until stable.

d. Slowly turn derivative potentiometer (3) clockwise (CW) until unstable, then counterclockwise (CCW) until stable. Adjusting derivative potentiometer may require a slight re-adjustment of the gain and stability potentiometers.

B. If the engine is unstable (hunting), use the following procedure to stabilize:

KG30 Governor Control Unit
(1) Gain potentiometer. (2) Stability potentiometer. (3) Derivative potentiometer. (4) Start fuel limit potentiometer.

a. If the engine has a rapid hunt, slowly turn the gain potentiometer (1) counterclockwise (CCW) until the engine is stable.

b. If the engine has a slow hunt, slowly turn the stability potentiometer (2) clockwise (CW). If the rate of hunt increases, slowly turn the stability potentiometer (2) counterclockwise (CCW). If unable to stabilize, slowly turn gain potentiometer (1) counterclockwise (CCW), then turn stability potentiometer (2) clockwise (CW), and if not successful, turn the stability potentiometer (2) counterclockwise (CCW).

c. At the most stable operating point, slowly turn the derivative potentiometer (3) clockwise (CW) until stability is optimum.

C. Manually upset the actuator terminal shaft lever several times, or step load the generator against a load bank to verify the engine returns rapidly to the set point speed with little overshoot or undershoot. If there is excessive overshoot or undershoot, or if the engine does not return to set point speed rapidly, re-adjust dynamic settings using the above procedure.

NOTE: Optimum performance is not necessarily obtained with the gain potentiometer at the maximum stable clockwise (CW) position. In some cases, the gain must be reduced slightly to ensure stability under widely varying conditions.

KG30 Governor Control Unit
(5) Stop 1.5V potentiometer. (6) Max speed potentiometer. (7) Droop potentiometer. (8) Max 5V potentiometer. (9) Min speed potentiometer. (10) Droop-Isoch switch.

7. Using the remote speed set point potentiometer, vary the engine speed between minimum and maximum several times to verify desired idle and rated speeds. Readjust the maximum (6) and minimum (9) speed potentiometers if necessary. Always adjust the maximum speed potentiometer (6) first, then minimum speed potentiometer (9).

NOTE: The maximum speed potentiometer is much less sensitive than the minimum speed potentiometer. Turn minimum speed potentiometer slowly to avoid sudden speed changes.

KG30 Governor Control Unit
(11) OV (-). (12) TP6 (+).

8. If it is difficult to adjust the stability of the engine due to engine noise or distance from the engine, connect an analog DC voltmeter (0 to 5 volt range or greater) to feedback voltage terminals marked TP6 (12) and OV (11). The stability of the engine will be reflected by the stability of the feedback DC voltage. Disconnect voltmeter when engine is stable.

9. Install cover on KG30 Governor Control Unit when dynamic adjustments are completed.

NOTE: The DC Feedback Voltage (which is read at TP6 (12) and OV (11) with a 0 to 5V DC high impedance voltmeter) can be used as an aid on a static or running engine during setup or in troubleshooting. The DC voltage is directly proportional to actuator angle, therefore indicating fuel rack position (although the DC voltage versus fuel rack position is not necessarily linear). For example, record the feedback voltage at important rack settings (Start Fuel Limit rack, rated load, no load). It is not necessary to read the rack indicator each time. Just read the feedback voltage to determine rack position. This is especially useful when the governor control unit is located far from the actuator or when working alone. Always disconnect voltmeter when finished with troubleshooting or setup, and never use the feedback voltage signal to power any external devices (such as variable pitch controllers, etc.).

Generator Set Applications

Generator Set Applications - KG30 Governor Control Unit Operated In Droop (LMG 03 Loadshare Unit Not Used)

Introduction

There are three common generator set applications for the Basic E30 Governor System where the KG30 Governor Control Unit can be operated in droop and the LMG 03 Loadshare Unit is not required. These applications are:

(1) Paralleling with the utility bus (constant frequency).

(2) Paralleling with a droop bus (changing frequency).

(3) Paralleling with a prime power (island) isochronous bus - one generator with isochronous governor, other generator(s) with droop governor(s).

The wiring schematic for these three applications is the Governor Connection Diagram on page 16 in the Initial Checks & Adjustments section.

Droop Definition

The DROOP control sets the amount of speed regulation for the engine. Since speed regulation is a function of load or power delivered, the DROOP function makes a reduction to the engine speed setting with an increase in load. The percent of speed droop is the difference between engine speed at No Load and engine speed at Full Load, and is calculated as follows:

Normally the percent of Droop is known, and the correction needed is the amount to increase the No Load setting. In this case, the No Load setting is calculated as follows:

(100% + % of Droop) × Full Load Setting = No Load Setting

For example:

(100 + 3%) × 60 Hz = 61.8 Hz

NOTE: If only 50% loading is possible, a No Load setting of 60.9 Hz would be an indication of 3% Droop as shown in the illustration for Droop Adjustment.

Droop Adjustment

Paralleling With Utility In Droop

The KG30 Control Unit is run with 3 to 5% droop and the LMG 03 Loadshare Unit is not used. The advantage of this setup is its simplicity: no current or potential transformer connections are made to the governor system and the additional LMG 03 Loadshare Unit is not needed. The disadvantage to this setup is the fact that the actuator will maintain a fixed fuel position related to the potentiometer setting, not a fixed power output. Variables that affect engine power, such as ambient air conditions, will also effect generator power output, as they do with a hydramechanical governor.

The engine is run at rated speed and the generator is paralleled with the utility. The remote speed set point potentiometer is turned clockwise (CW) to increase the engine speed setting, but the engine speed is locked at the bus frequency, so the governor goes to an increased fuel position. In this way the remote speed set point potentiometer becomes the load adjusting potentiometer once the generator is paralleled to the utility.

The KG30 must be set for droop (see Droop Adjustment in Initial Checks & Adjustments). Increasing the percent droop (CW rotation of droop potentiometer) allows for finer adjustment of the generator output and greater system stability. If the KG30 is accidentally put in the isochronous mode, the operator will be able to parallel the generator, but the actuator will slowly increase or decrease fuel to full rack or shutoff.

Setup Procedure

KG30 Governor Control Unit
(1) Max speed potentiometer. (2) Droop potentiometer. (3) Droop-Isoch switch.

1. Put KG30 Droop-Isoch switch (3) in droop mode (left most position). Follow "Procedure 4. Droop Adjustment" in the Initial Checks & Adjustments section. With the remote speed set point potentiometer set for rated speed (fully clockwise [CW]), adjust the max speed potentiometer (1) until the maximum speed of the KG30 is set 2 to 5% above rated speed of the engine at the rated power rack setting of the engine. When the load potentiometer of the governor test unit is adjusted to the no load-rated speed position, the engine speed read with the governor test unit should droop up by the amount of droop previously set in the KG30, which is usually 3 to 5%.

2. Verify KG30 is adjusted correctly by paralleling generator, then turning the remote speed set point potentiometer (which is now functioning as the load potentiometer) slowly clockwise (CW) until the rated output of the generator is reached.

3. If the rating of the engine (in millimeters of injector rack) cannot be reached with the remote speed set point potentiometer turned fully clockwise (CW), it indicates that the max speed potentiometer (1) is set too low or that the percent droop is set too high. Remedy the problem by either increasing the maximum speed of the KG30 (CW rotation of the max speed potentiometer [1]) or reducing percent droop (CCW rotation of the droop potentiometer [2]). Remember, decreasing the percent droop decreases the sensitivity of the load potentiometer and can decrease system stability.

4. To take the generator off the utility bus, slowly turn remote speed set point potentiometer counterclockwise (CCW) until the generator output is zero, then open the breaker.

Paralleling With A Droop Bus

This application is used when paralleling with other generators governed by hydramechanical governors operated in droop. This type of application may be found on some older prime power (island) sites that were built before isochronous electric loadshare governors were available. The setup is similar to the setup for paralleling to a utility bus, except the percent droop must be matched to the existing units for accurate load sharing over entire load range.

Setup Procedure

KG30 Governor Control Unit
(1) Max speed potentiometer. (2) Droop potentiometer. (3) Droop-Isoch switch.

1. Determine the no load-rated speed and rated load-rated speed of the other engine(s) on the bus. Use this information to calculate the percent droop.

2. Put KG30 Droop-Isoch switch (3) in droop mode (left most position). Follow "Procedure 4. Droop Adjustment" in the Initial Checks & Adjustments section. Set the KG30 to the same no load-rated speed and full load-rated speed determined in Step 1 above.

3. To verify settings, remove all load from the engine. Run engine at no load-rated speed, and slowly apply 100% load. If the full load speed is now higher than the desired speed determined in Step 1, turn droop potentiometer (2) slowly clockwise (CW) to increase droop (reduce speed) to desired speed. If the full load speed is too low, turn droop potentiometer (2) slowly counterclockwise (CCW) to reduce droop (increase speed) to desired full load-rated speed.

4. Parallel the new generator to the bus. Adjust the remote speed set point potentiometer, which is now functioning as a load potentiometer, until the generator is running at the same percent of its rating as the existing generators. Add and remove load to the bus to verify all generators are sharing load equally.

Paralleling With A Prime Power (Island) Isochronous Bus One Generator With Isochronous Governor, Other Generator(s) With Droop Governor(s)

This application may be used at a prime power (island) installation having a relatively constant basic load. One generator is operated with its governor set for isochronous operation, while the governor(s) of the other generator set(s) are set for droop operation. The generator(s) operated in droop take(s) a constant base load, adjusted by turning the remote speed set point potentiometer. The generator with the isochronous governor takes the load changes and keeps the bus frequency constant.

Setup Procedure

KG30 Governor Control Unit
(1) Max speed potentiometer. (2) Droop potentiometer. (3) Droop-Isoch switch.

1. If the generator to be run isochronous has a KG30 Governor Control Unit, put its Droop-Isoch switch (3) in isochronous mode (right-most switch position). The internal max speed potentiometer (1) of the KG30 is set about 2% above rated speed to allow fine adjustment of the rated engine speed by the remote speed set point potentiometer. If generators with various ratings will be on the bus, use the generator with the highest rating for isochronous operation.

2. The other generator(s) are set up to have a full load-rated speed of about 2% above rated speed and 3 to 5% droop. The percent droop is not critical with this application, but increasing the percent droop increases the system stability and increases the sensitivity of the remote speed set point potentiometer, which functions as the load adjusting potentiometer once the generator is paralleled.

3. The generator with the isochronous governor is paralleled onto the bus. Some load is then applied to the generator.

4. The first generator with the droop governor is then paralleled onto the bus and more load is added. The amount of base load that this generator takes is adjusted by turning the remote speed set point potentiometer. Turning the potentiometer clockwise (CW) increases generator output.

5. If there are additional generators with droop governors, they are paralleled onto the bus following Step 4 above.

6. Generators with droop governors can be added and taken off the bus to maximize generator use and efficiency, but there must always be one generator running on the bus in isochronous mode to keep a constant bus frequency and to take load changes.

NOTE: Two or more generators with isochronous loadshare governors sharing load with each other can replace the single generator run isochronous as described above.

LMG 03 Loadshare Unit

Wiring Schematics

Basic System Schematic For Kilowatt Load Sharing
(5) StG30 Actuator. (6) Engine. (7) Feedback line. (8) Magnetic pickup. (9) Fuse. (10) KG30 Governor Control Unit. (11) Remote speed set point potentiometer. (12) LMG 03 Loadshare Unit. (13) Generator. (14) Paralleling lines. (15) Bus.

Visual Inspection

Using the basic loadsharing wiring diagram on page 41, verify the following:

(1) Wiring matches the application: prime power (island), paralleled with utility, droop operation, etc.

(2) Wires are the correct diameter and shielded correctly.

(3) No broken, loose or missing wires.

(4) T2, T3 and T4 are used with 380V AC potential transformers, or T2A, T3A and T4A are used with 200V AC potential transformers.

(5) T1 and 115V are used for 115V AC supply voltage to LMG 03, T1 and 220V are used for 220V AC supply voltage.

(6) If any accessory (such as a synchronizer) is used, verify it is wired correctly according to the system wiring schematic.

Checking The Shield, Supply Power And Potential Transformers

Checking The Shield

If terminal 19 is used, turn power off to the LMG 03 and remove wire(s) from terminal 19. Connect ohmmeter between wire(s) removed from terminal 19 and battery ground (-). The ohmmeter should read open circuit (infinite ohms). If it does not read open circuit, determine point of unwanted connection in the shield and remove it, then reconnect wires to terminal 19.

See system wiring diagram to determine if shielded wire is used for other connections to the LMG 03. If additional wires are shielded at the LMG 03, verify the wires are shielded correctly using the above procedure.

Checking The Supply Power

With powpr supply still off, disconnect common wire from T1. Put multimeter in 0 to 1000V AC mode, connect voltmeter leads between wire taken off of T1, and 115V or 220V, whichever terminals are used, to measure LMG 03 supply voltage. Make sure the wire from T1 does not contact anything but the voltmeter lead.

Turn on power to LMG 03 and read supply power. It must be 115V AC ± 15% or 220V AC ± 15%. If the supply power is in either of the two ranges, turn off supply power to LMG 03 and reconnect common wire to T1. Make sure the supply wire goes to the correct terminal; 115V AC nominal to terminal 115V or 220V AC nominal to terminal 220V.

Potential Transformer Voltage Check

Start engine and run at rated speed. Using the voltmeter in 0 to 1000V AC range, measure the AC voltage across the appropriate three terminals inside the LMG 03 as follows:

For 380V AC nominal phase-phase potential transformers;

T2-T3, 320 to 440V AC (3 wire phase-phase)T3-T4, 320 to 440V AC (3 wire phase-phase)T2-T4, 320 to 440V AC (3 wire phase-phase)T2-T3, 185 to 255 V AC (4 wire phase-neutral)T3-T4, 185 to 255V AC (4 wire phase-neutral)T2-T4, 185 to 255V AC (4 wire phase-neutral)

For 200V AC nominal phase-phase potential transformers;

T2A-T3A, 170 to 230V AC (3 wire phase-phase)T3A-T4A, 170 to 230V AC (3 wire phase-phase)T2A-T4A, 170 to 230V AC (3 wire phase-phase)T2A-T3A, 100 to 130V AC (4 wire phase-neutral)T3A-T4A, 100 to 130V AC (4 wire phase-neutral)T2A-T4A, 100 to 130V AC (4 wire phase-neutral)

If these three voltages are not the same and in the correct range, verify that the potential transformer connections are as shown on the basic loadshare wiring diagram on page 41.

Reverse Power Relay

LMG 03 Loadsharing Unit
(1) Reverse power relay link (Br4). (2) Reverse power LED (LD4).

Reverse Power Relay Link (Br4)

The LMG 03 contains a reverse power relay. The relay will operate after three seconds of reverse power. The level of reverse power can be either 5% or 10%. With the reverse power relay link (1) in position (A) switching occurs at 10% reverse power and with the link in the storage position (B) switching occurs at 5% reverse power, when 5 amp current transformers are used. When less than 5 amp current transformers are used, the level of reverse power switching will be proportionally less. The reverse power LED (2) will also be lit. Switching of the relay and lighting of the LED will occur if one or more of the phases goes to reverse power.

Terminal T29 is common for the reverse power relay. With normal power on all three phases T29 & T30 will be normally closed and T28 normally open. Upon closing of the reverse power relay, T28 & T29 will be closed and T30 open. The contact load of the reverse power relay can be a maximum of 8 amps at 250V AC.

Dynamic Adjustments And Settings

LMG 03 Basic Setup Procedure

All Applications

The basic wiring schematic for all generator applications using the LMG 03 Loadshare Unit is the basic loadshare wiring diagram found on page 41. See specific applications which follow for any removal or addition of wiring and/or hardware to the basic diagram.

For all applications, perform procedures 1 through 6 for each generator, one at a time.

KG30 Governor Control Unit
(1) Droop-Isoch switch.

(1) Verify the KG30 Governor Control Unit Droop-Isoch switch (1) is set to Isochronous mode (right most position of droop-isochronous switch).

LMG 03 Loadshare Unit
(1) Current flow links. (2) Reverse current flow LED's. (3) Gain potentiometer. (4) Droop potentiometer. (5) Max. load potentiometer.

Current Flow Links (Br1, Br2, Br3)

(2) On LMG 03, turn GAIN potentiometer (3) to 10 (fully CW), DROOP potentiometer (4) to 0 (fully CCW) and MAX. LOAD potentiometer (5) to + (fully CW). The LMG 03 should come from the factory at these settings.

(3) Start the engine. Set the no load speed as precisely as possible: 50 Hz, 60 Hz, etc. Put 100% load on the engine if available. Do not parallel the generator. 100% load is not required, but a steady load is required.

(4) Observe the reverse current flow LED's (2) to verify correct connections of the current transformers. If one of more of the LED's is lit, the current transformer for that phase is connected backward. To temporarily correct the connection, change the appropriate current flow link (1) from the standard position (A) to the reverse position (B) to effectively reverse the current transformer connection and the lit LED should go out. For example, if LED LD1 is lit, the current transformer for phase 1 is connected backward and can be corrected by reversing current flow link "BR1".

This can be done while the engine is running, using a needle nose pliers with insulated grips. Later, when the engine is shutdown, reverse the current transformer connection(s) for the phase(s) where the current flow link(s) (1) were reversed. The current flow links (1) should all be returned to the standard position (A) before the generator installation is put into service. This will insure the correct current transformer connections in the event that the LMG 03 is ever replaced.

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Never connect or disconnect current transformer leads from the LMG 03 Loadshare Unit (terminals 5 through 10) when the engine is running. The current transformers can develop high voltages when open circuited with unit loaded, and can result in serious injury or death to personnel.

(5) Connect the multimeter in 0 to 20V DC mode to TP10 (+) (6) and TP11 (-) (7). As an alternative, the voltmeter can be connected to T12 (+) and T16 (-). Adjust the GAIN potentiometer (3) until the voltmeter reads 6V DC at 100% load. This voltage is proportional to generator load, so if full load is not available, adjust the GAIN to this ratio (ie, 50% load is 3V DC, 25% load is 1.5V DC). If the potential transformers are connected phase-neutral, a maximum GAIN voltage of 6V DC may not be attainable. If this is the case, adjust the GAIN to the maximum attainable value below 6V DC.

(6) One at a time, short circuit the current transformers for several seconds by shorting between terminals 5 and 6, then 7 and 8, and 9 and 10. Only have one pair of terminals shorted at a time. The gain voltage read at TP10 (6) and TP11 (7) must decrease by 1/3 each time (for example from 6V DC to 4V DC). If the gain voltage does not decrease each time, check current transformer connections. The gain voltage must decrease by 1/3 when each current transformer is shorted before going to the next step.

LMG 03 Loadsharing Unit
(6) TP10. (7) TP11.

Specific Applications

A. Prime Power (Island) Isochronous Load Sharing (Not Paralleled To Utility)

(1) Verify "LMG 03 Basic Setup Procedure" was performed for each generator.

(2) To load share with the other generator(s), proceed as follows:

(a) Run first generator at rated speed, bring onto bus. Load the first generator with 50% load. Start up second engine, synchronize onto bus, and it should take 1/2 of the load.

LMG 03 Loadsharing Unit
(1) Gain potentiometer.

(b) Increase load to 100%. If there is unequal load sharing, adjust the GAIN potentiometer (1) setting of the second loadshare unit. Turning the GAIN counterclockwise (CCW) increases load.

(c) Check at no load. If there are load differences between the two generators, it is caused by the two generators not being set at precisely rated speed. To correct this problem, take the second generator off the bus and set each engine at precisely rated speed with the remote speed set point potentiometer. Parallel the second generator again and recheck at no load and rated load.

(d) Take generator two off the bus. It is set up. Now proceed to parallel generators one and three, one and four, etc. following this same procedure. Since generator one and two are now set up, only make adjustments to the newly added generator (3, 4, 5 etc).

(3) If load hunting occurs between the generators, reduce the GAIN voltage set in Step 5 from 6V DC to 5V DC at 100% load for all generators on the bus. If there is still some load hunting, decrease this GAIN voltage further to 4V DC for all generators.

(4) Remember, unequal load sharing at no load is corrected by adjusting the remote speed set point potentiometer of the KG30 Governor Control Unit, while unequal load sharing at full load is adjusted with the GAIN adjustment of the LMG 03 Loadshare Unit.

B. Prime Power (Island) Load Sharing In Droop

Load sharing in droop with the LMG 03 is used when other generators on the bus have mechanical droop governors or when the entire bus is run in droop. This type of application may be found on some older prime power (island) sites that were built before isochronous loadshare governors were available. The advantage to using the LMG 03 operated in droop over using only the KG30 in droop and not using the LMG 03 is the method of calculating droop.

The LMG 03 calculates droop as a function of generator output, while the KG30 calculates droop as a function of actuator angle using the feedback signal. Therefore, the droop calculated by the LMG 03 is not affected by engine variables such as actuator linkage, injector differences, air conditions, etc., as is the case with the KG30. In this way the LMG 03 provides for a constant generator output at a given rpm.

(1) Verify that there are no wires connected to any of the following terminals: 17, 18, 19, 20, 21, 23 and 24. If wires are connected to any of these terminals, they must be removed to run in droop.

(2) Verify "LMG 03 Basic Setup Procedure" was performed for each generator.

(3) The percent droop of the other engines on the bus must be known so that the units with the LMG 03 can be matched for load sharing. See "Generator Set Applications, Droop Definition" for a detailed description of droop.

LMG 03 Loadshare Unit
(1) Droop potentiometer.

KG30 Governor Control Unit
(2) Maximum speed potentiometer.

(4) With all load off the newly installed generator, run engine at no load-rated speed. Load the generator to 100% rated power. Slowly turn the LMG 03 droop potentiometer (1) clockwise (CW) to about the 5 mark on the scale as a starting point. The engine speed will drop. Adjust the remote speed potentiometer of the KG30 until the full load-rated speed, determined in Step 3, is reached. If the full load-rated speed can not be reached, the maximum speed potentiometer (2) inside the KG30 may have to be readjusted.

(5) Slowly take all of the load off the generator. If the no load-rated speed is the same as the no load-rated speed determined in Step 3, the unit is set. If the no load-rated speed is lower than the no load-rated speed determined in Step 3, turn the LMG 03 droop potentiometer (1) slightly clockwise (CW) to add droop. If the no load-rated speed is higher than in Step 3, turn LMG 03 droop potentiometer (1) slightly counterclockwise (CCW). Repeat Steps 4 and 5 until the droop of the new generator is the same as the droop of the existing generators on the bus.

(6) Repeat Step 4 and 5 for all of the new generators on the bus. The droop of each individual generator must be set the same as the existing unit(s) for accurate load sharing.

(7) To verify the generators are load sharing correctly, parallel the new generators with the bus, add and remove load, and check to see that all generators are sharing load equally.

C. Utility Operation - Load Adjustment, One Or More Generators Paralleled With The Utility (Infinite Bus)

This setup is used to adjust the generator output when a single generator is paralleled with the utility, when multiple generators are paralleled with the utility and a single load adjustment is desired, or when multiple generators are run part time prime power (island), part time paralleled to the utility.

(1) Verify "LMG 03 Basic Setup Procedure" was performed for each generator.

Basic Wiring Schematic
(1) 15K ohm fixed resistor. (2) 5K ohm potentiometer (load adjusting). (3) Relay. (4) Utility breaker.

(2) To adjust the output(s) of one or more generators with one potentiometer, a 5000 ohm load adjusting potentiometer (2) is wired into only the first loadshare unit as shown. When wired as shown, the one potentiometer will adjust the output(s) of the generator(s) together by sending the same load signal to all loadshare units.

NOTE: If two or more generators are electrically tied together with the single load adjusting potentiometer, the generators must also be set up following "Procedure A. Prime Power (Island) Isochronous Load Sharing" to verify they are sharing load equally and that there is no load hunting.

(3) Turn the load adjusting potentiometer (2) fully counterclockwise (CCW). Parallel the generator with the utility.

(4) Turning the potentiometer (2) clockwise (CW) will increase the output of the generator. The generator output will be adjustable up to the rack stop setting of the engine, or to the LMG 03 load limit, whichever is set lower.

(5) To adjust the maximum load limit, see Procedures D and E which follow.

D. Utility Operation - Setting Of Internal Maximum Load Limit

Electrical Connection (Internal Maximum Load Limit And Remotely Set Maximum Load Limit)

(1) Load limiting can only be used when paralleled with the utility. Therefore, connect terminals 24 and 27 of each LMG 03 to auxiliary contacts in the main breaker as shown.

(2) Verify that "Procedure C. Utility Operation - Load Adjustment" was performed.

Basic Wiring Schematic (Load Adjustment)
(1) 15K ohm fixed resistor. (2) 5K ohm potentiometer (load adjusting). (3) Relay. (4) Utility breaker.

LMG 03 Loadsharing Unit
(4) Max load potentiometer.

(3) Verify that the LMG 03 Loadsharing Unit "Max Load" potentiometer (4) is fully clockwise (CW).

(4) Parallel the generator with the utility. Set the generator load 3 to 5% higher than the desired load limiting setting with the load adjusting potentiometer (2). See "Procedure C. Utility Operation - Load Adjustment". This must be less than the rack stop power setting. Verify that the actuator is not against the rack stop.

(5) Slowly turn the LMG 03 "Max Load" potentiometer (4) counterclockwise (CCW) until the generator output is at the desired level. The load limit is adjustable from approximately 50 to 100% full power.

(6) This will now be the maximum output of the generator. The generator output will be adjustable up to this maximum setting using the load adjusting potentiometer (2). Verify by turning load adjusting potentiometer (2) from full counterclockwise (CCW) to fully clockwise (CW).

E. Utility Operation - Remotely Set Maximum Load Limit

With this option, the load limit of the generator can be adjusted remotely, away from the LMG 03, with a 5000 ohm potentiometer. This is the same load limit that was set internally in "Procedure D. Utility Operation - Setting Of Internal Maximum Load Limit". This applies to a single or multiple isochronous generator installation paralleled with the utility.

Electrical Connection (Remotely Set Maximum Load Limit)
(1) 5K ohm potentiometer (remote load limit).

(1) Connect the 5000 ohm remote load limit variable potentiometer (1) as shown. One potentiometer is needed for each LMG 03. Turn the potentiometer (1) fully clockwise (CW).

(2) Load limiting can only be used when paralleled with the utility. Therefore, connect terminals 24 and 27 of each LMG 03 to auxiliary contacts in the main breaker as shown.

LMG 03 Loadsharing Unit
(2) Max load potentiometer.

(3) Turn the LMG 03 Loadsharing Unit "Max Load" potentiometer (2) fully clockwise (CW).

(4) Verify that "Procedure C. Utility Operation - Load Adjustment" was performed.

(5) Parallel the generator. Adjust the load adjusting potentiometer (4) 3 to 5% higher than the desired load limiting setting. See "Procedure C. Utility Operation - Load Adjustment". This must be less than the rack stop power setting. Verify that the actuator is not against the rack stop.

(6) Slowly turn the remote load limit adjusting potentiometer (1) counterclockwise (CCW) to decrease the load limit to the desired level.

Basic Wiring Schematic (Load Adjustment)
(3) 15K ohm fixed resistor. (4) 5K ohm potentiometer (load adjusting). (5) Relay. (6) Utility breaker.