Manual GAC - SDG
Manual GAC - SDG
G OVERNORS
Purpose
The purpose of this manual is to provide the necessary information for installing, wiring, configuring and troubleshooting the
SDG 500 Series (Smart Digital Governor). The target audience for this manual is OEMs, however OEMs should feel free
to copy the needed information from this manual into their application service manuals.
This version of this manual applies to all SDG500 Series models. There are four variations of the SDG500 Series:
TABLE 1.
Recommended Cable Mating
Model Description Pins
Connection
SDG510 Deutsch connector DT06-12SA & W12S 0462-201-16141
SDG511 Molex connector 0015975121 0457501111
Intended Application
The SDG 500 Series (Smart Digital Governor) is designed to regulate engine speed on diesel and gas/gasoline reciprocating
engines. The SDG 500 Series (Smart Digital Governor) is a suitable replacement for any mechanical system that needs
more flexibility, precision or control in governing speed. The SDG 500 Series is an integral part of a closed loop control.
When connected to an electric actuator and supplied with a magnetic speed sensor signal, the governor will direct the
engine to the desired speed setting. The SDG 500 Series (Smart Digital Governor) is designed for industrial applications
ranging from generators and mechanical drives to pumps and compressors.
Compatible Products
Actuators
All GAC actuators, except ACB2001*
* Connections to actuator may vary. Consult factory for compatibility.
Mag Pickups
All GAC magnetic pickups
The factory standard SDG500 Series is pre-programmed to OEM’s specifications. The SDG510 and SDG511 have no
end user modifiable settings. The SDG512 and SDG513 are equipped with a single turn gain trim potentiometer for field
adjustments.
If needed, configuration and tuning of the SDG500 Series can be accomplished by the OEM via GAC’s configuration software.
The software allows users to save the current configurations and data to disk or file. Saved settings can be utilized for
configuring multiple units.
Installation
1.3 Optional
USB/Serial Adapter
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BEFORE BEGINNING INSTALLATION
Disconnect all battery power to the engine. Make sure the engine cannot operate during installation. Follow all safety warn-
ings of the machine manufacturer. Read and follow instructions carefully.
Please read the following instructions and visually inspect this product for damage from shipping before installing. It is your responsibility
to have a qualified person install this unit and make sure it conforms to local codes.
Locate the SDG Series control a distance from extreme heat, wires or coils. Operating temperature range is from -40º to
85º C (-40º to 185ºF).
See DIAGRAM 1 & 2. (for the SDG510 & SDG512) and DIAGRAM 2. (for the SDG511 & SDG513).
1. To mount the SDG to a panel, drill 2 (4.7mm dia / Ø.184 drill size) holes for mounting screws. Place module in front
of the panel aligning with the pre-drilled holes. Secure the module in place with two M-4 screws.
44.5
DIAGRAM 1. 1.751
MOUNTING FOR SDG510 & SDG512
22.3
Deutsch connector .878
52.1
2.052
cable length 26.1
2X 1.026
approximately 2,000 mm
101.7
4.004
DIAGRAM 2.
22.3
MOUNTING FOR SDG511 & SDG513 .878
Molex connector
TOP VIEW 4.7
2X Ø .184
52.1
2.052
26.1
cable length 2X 1.026
approximately 2,000 mm
88.9
3.500 SIDE VIEW
101.7
4.004
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Please read the following instructions and visually inspect this product for damage from shipping before installing. It is your responsibility
to have a qualified person install this unit and make sure it conforms to local codes.
The SDG 500 Series control has an operating range of 10 to 32 VDC with nominal voltage range of 12 or 24 VDC.
1. Use a hand crimping tool to connect wires to the recommended cable connector (see TABLE 2.).
TABLE 2.
SDG510 and SDG512 SDG511 and SDG513
use the below listed DIAGRAMS and TABLES use the below listed DIAGRAMS and TABLES
General Wiring Instructions General Wiring Instructions
DIAGRAM 3. DIAGRAM 4.
TABLE 3 & 5. TABLE 4 & 5.
Deutsch Cable Connector DT06-12SA & W12S Molex Cable Connector 0015975121
Deutsch Pins 0462-201-16141 Molex Pins 0457501111
2. For specific wiring instructions on Connector Pins 2 & 3 for the Deutsch & Molex Cable Connector see
TABLE 5.
3. Battery connections to Connector Pins 1 & 5 for both the Deutsch & Molex Cable Connector should be
16AWG (18mm2 ) or larger. Long cables require an increased wire size to minimize voltage drops.
4. Battery positive(+) input to Connector Pin 1 for the Deutsch & Molex Cable Connector should be fused for
15A.
5. The Magnetic Speed Sensor connections to Connector Pin 11 on the SDG510 & SDG512 and to Connector
Pin 8 on the SDG511 & SDG513 must be twisted and/or shielded for their entire length. The speed sensor
cable shield should be connected to ground.
6. The shield should be insulated to insure that no other part of the comes in contact with engine ground, otherwise
stray signals may be introduced into the SDG500 Series causing erratic operation.
7. Connect the GAC Standard Two Wire Actuator Connector to the connector on the actuator.
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DIAGRAM 3.
WIRING PIN OUT SDG510 & SDG512 15 AMP
FUSE
DEUTSCH CABLE CONNECTOR
SPEED Released
12/24 VDC SELECT
Released
1 2 3 4 5 6
12 11 10 9 8 7
12/24 VDC
NC NC
MAGNETIC
PICK-UP
10K
POT
NC
TABLE 3.
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DIAGRAM 4.
WIRING PIN OUT SDG511 & SDG513 15 AMP
MOLEX CABLE CONNECTOR FUSE
SPEED
12/24 VDC SELECT
Released
Released
1 2 3 4 5 6
7 8 9 10 11 12
NC NC
MAGNETIC
PICK-UP
10K
POT
NC
TABLE 4.
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TABLE 5.
All SDG500 Series
Speed Select
Connector Pin 2 Connector Pin 3
No Connect No Connect Variable Speed*
No Connect Battery - Fixed Speed 1
Battery - No Connect Fixed Speed 2
Battery - Battery - Fixed Speed 3
1. Connect the Bypass Cable Harness between the Mounted Connector on the top side of the SDG and the
GAC SDG 500 Series Engine Cable Harness.
2. Connect the DB9 connector on the Bypass Cable Harness to your PC. Optional: Connect using an USB/
Serial Adapter.
3. (SDG512 & SDG513 only) Set gain trim adjustment to mid-point.
4. Power ON the unit.
The software for the SDG does not affect the registry rights of your operating system and therefore is easy to install.
Simply copy the file SDG.exe to the desired location and double click to execute.
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Figure 1.
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1. To open the Grid Configuration window, select Configuration from the drop down menu and choose Grid.
2. Choose the option button to the left of Enable to allow for the meter and the configurable parameter windows to
snap to a grid. (See Figure 2.)
3. Select a color option.
4. Select a grid size. This will configure the distance from point to point in pixels.
5. Click OK to save/exit the Grid Configuration window.
Figure 2.
8.0 Organizing the Meters and Configurable Parameters on the Grid Desktop
The meters provide real-time metering that updates approximately every half-second. Meter windows are read only. The
configurable parameters windows are editable.
1. To open the Meter Manager, select Meters from the drop down menu and choose Configure. (see Figure 3.)
2. Click to highlight the connection that you are currently using.
3. Click on the Meters Tab to select meters. Double click on a meter or single click to highlight a meter and click
the Add Meter button to add a meter listed in the scroll box on to the grid. Once placed on the grid, the meter
windows can be arranged on your desktop by clicking to hold and dragging the window to best fit your needs.
Figure 3.
4. Repeat the above process to place the Configurable Parameters on the grid and for the Calibration.
5. Exit the Meter Manager by single clicking on the top right Cancel Option Box of the window. (Please note that
this does not save the settings. For saving the setting, please refer to SECTIONS 9.0 and 9.1)
This document is subject to change without notice.
Caution: None of GAC products are flight certified controls including this item.
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8.1 Description of Configurable Parameters
Setting and values are based on number of teeth on the flywheel and therefore ranges may vary.
ADC max Max RPM value from the SDG analog to digital converter. Read only
ADC min Min RPM value from the SDG analog to digital converter. Read only
Build Date
Read only
Crank
! Termination
RPM set point for crank termination. When the engine RPM exceeds the crank termination set point, the SDG switches
from start up cycle to PID loop control. This parameter must be set higher than the maximum cranking RPM.
yes
! Derivative
PID. Derivative mode is a breaking action to the controller response as the process variable approaches the set point. yes
Droop 1
Droop 2
Droop 3
Not Activated
Droop Variable
Speed
External Gain
Fixed Speed 1 Desired RPM set point when the speed select input is set to 1. yes
Fixed Speed 2
Desired RPM set point when the speed select input is set to 2. yes
Fixed Speed 2
Desired RPM set point when the speed select input is set to 3. yes
Fuel Limit The percentage limiter set point on the fuel demands that prevents the over fueling after the engine has started. yes
! Gain PID. Proportional mode responds to a change in the process variable proportional to the current measured error value. yes
! Gain Enabled Turns the external gain pot on an off. Available only in the SDG512/13. yes
! Overspeed
RPM Set Point for an Engine Shutdown Signal to the actuator. yes
RPM max
Maximum RPM set point for Variable speed Read only
RPM min
Minimum RPM set point for Variable speed Read only
Serial Number
System Information. Read only
Software Version
System Information. Read only
Speed Ramp
Down The % percent set point to decrease engine speed per second when changing speeds. yes
Speed Ramp Up
The % percent set point to increase engine speed per second when changing speeds. yes
Speed Request
Desired speed of engine at the current state. yes
! Stability
PID. In integral mode, the controller output is proportional to the amount and duration of the error signal. yes
Gradually increases the amount of fuel during the engine crank cycle, which eliminates most unnecessary
Starting Fuel
smoke. The higher the setting the quicker the engine comes to speed. The starting position of the actuator at
Ramp yes
engine start. The percent to increase the fuel flow per second until the engine reaches 100% or the governors
takes control.
Starting Fuel
Determines how much fuel to begin with before fuel ramping engages. The minimum fuel required for starting
Start Point yes
the engine. Retards black smoke. The starting position of the actuator at engine start.
! Teeth
Number or teeth on the flywheel. Used to calculate speed settings and values. yes
Velocity
Actual RPM of engine. Read only
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8.2 Recommended Screen Layout for Configuration
Before starting engine safety, basic parameters on the SDG must be configured.
Refer to FIGURE 4 & TABLES 6-10 for guidelines.
TABLE 6.
Screen Section 1. Basic Parameters that must be configured before start.
Configurable Parameters Instruction Critical
Settings
Teeth Configure first. Used to calculate values and settings. !
Overspeed Set typically 10% above desired governing speed. !
This parameter must be set higher than maximum cranking RPM. This set point helps the
Crank Termination !
SDG determine in the engine is cranking or running.
Speed Select 1, 2, 3 Insure that the Speed Select is wired correctly (see TABLE 5). Set RPM in the appropriate !
Fixed Speed window.
Variable Speed Operation Make sure the Variable Speed Potentiometer is connected correctly (see DIAGRAM 3 & 4). !
Set the RPM min and max on the Speed Potentiometer Calibration Screen. Click on the
Calibration button. Set the Minimum position on the potentiometer and then click on the Con-
tinue button. Set the Maximum position on the potentiometer and then click on the Continue
button. Click OK on the popup window to calibrate.
ADC min and max (meter) Represents the min and max values set on the Variable Speed Potentiometer.
FIGURE 4.
4
3
5
This document is subject to change without notice.
Caution: None of GAC products are flight certified controls including this item.
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TABLE 7.
Screen Section 2. Read Only Meters
Meter Description
Speed Request Displays the speed requested for the current state.
Velocity Displays the SDG’s reading of Actual RPM Engine.
TABLE 8.
Screen Section 3. Advanced configurations that do not need to be configured before starting the engine.
Configurable Parameters Instruction
Started Fuel Ramp Gradually increases the amount of fuel flow per second during the engine crank cycle, which eliminates most
unnecessary smoke. The higher the setting the quicker the engine comes to speed.
Starting Fuel Start Point Determines how much fuel to begin with before fuel ramping begins.
Speed Ramp Up The % percent set point to increase engine speed per second when changing speeds.
Speed Ramp Down The % percent set point to decrease engine speed per second when changing speeds.
Fuel Limit Adjusts maximum amount of fuel the SDG will command. During normal starting cycles and short step loads,
this function will not engage. Only after a 1 second delay of the Fuel Limit exceeding it’s configured value, then
the fuel will roll back to the configured value. Helps to reduce engine smoke and prevents engine damage.
TABLE 9.
Screen Section 4. PID Parameters. Must be adjusted after the engine starts for best performance.
Configurable Parameters Instruction Critical
Settings
Gain The PID screens are adjustable by only increments of 1 or 2. Choose increments by select- !
ing the appropriate option button. The use the UP and DOWN buttons for fine tuning.
Stability !
Derivative !
Gain Enabled Select YES or NO to turn the GAIN Adjustment ON or OFF. (SDG512 & SDG513 only)
Total Gain The sum of Internal and External Gain. (SDG512 & SDG513 only)
TABLE 10.
Screen Section 5. Read Only Meters
Meter Description
Serial Number
Software Version System Information.
Build Date
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1. Select File from the drop down menu and choose Save.
2. Name the file and save to desired location.
Please note that the above procedure saves only the layout of the meters & configurable parameters windows and not the
actual changes to the configurable parameters. (see section 5.2 Saving Configurable Parameters)
The file extension for Saving Layout of Grid Desktop is (.sfg) and the file extension for Saving Configurable
Parameters is (.all).
1. Select Configure from the drop down menu and choose Save to File.
2. Click to highlight the connection currently in use and single click on the Save to File button.
3. Name the file and save to desired location.
4. Click on the OK button on the Save to FIConfMngr window to acknowledge that parameters have been saved to
file.
5. Exit the Configuration Manager by single clicking on the top right Cancel Option Box of the window.
1. Select File from the drop down menu and choose Open. Find the saved settings (file extension .sfg).
2. Click the OK button to accept on the Configuration File Connection window.
3. The Open Configuration File Manager window should appear.
4. Verify that the appropriate connection is highlighted.
5. Single click on the Connect button to connect. The Check Status window should appear, click OK to accept.
6. Exit the Connection Manager by single clicking on the top right Cancel Option Box of the window.
1. Select Configuration from the drop down menu and choose Load to File.
2. Click to highlight the connection.
3. Click on the Load from File button and locate the saved settings (file extension .all).
4. Click on the OK button Load from Configuration Manager window to accept. 5. Exit the Configuration Load
from File Manager by single clicking on the top right Cancel Option Box of the window.
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1. Turn ON Power and Open saved Screen layout. (see Section 6.1)
2. Load saved parameters. (see Section 6.2)
3. Select Connections from the drop down menu and choose Configure.
4. Click to highlight the connection currently in use.
5. Single click on the Disconnect button to disconnect.
6. Turn the power supply OFF on the SDG.
7. Disconnect all the connections to the SDG.
8. Reconnect all the wires to the a new SDG unit for configuring. (see Sections 2 & 3)
9. Loads setting onto new SDG unit. (see Section 6)
10.1 Disconnecting
1. Select Connections from the drop down menu and choose Configure.
2. Click to highlight the connection currently in use.
3. Single click on the Disconnect button to disconnect.
1. Measure the battery voltage while attempting a crank. If the voltage drops below 8 Volts then the battery is not
sufficiently charged.
2. Check that the actuator voltage is no less than 2 volts less than battery voltage. If the actuator voltage checks then
verify the proper connection of the actuator.
3. Check Crank Termination setting. Typically the Crank Termination should be set to at least 50RPM higher than the
maximum cranking speed of the engine. If possible measure the cranking RPM of the engine. You can try increasing
in 100RPM increments. If engine appears to start but cuts out then the Fuel Limit may be too low. Try increasing the
Fuel Limit to 100% initially to disable the Fuel Limiting. If the engine starts, the Fuel Limit will have to be reduced
from 100% to more optimum level.
4. Verify the Mag Pickup signal is properly connected. If possible measure the pickup signal while the engine is
cranking. The voltage must be a minimum of 05.VRMS for proper operation.
5. If possible through the PC Configuration software check the Starting Fuel Limit and the Starting Fuel Start Point.
6. Check set to a shorter time of Fuel Ramp Up through the PC configuration software.
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1. Are the fixed speed inputs properly configured. If one or both of the fixed speed inputs is not connected to ground
the SDG will operate in variable speed mode.
2. Make sure the correct number if flywheel teeth is set using the configuration software.
3. Make sure the proper fixed speed is set using the configuration software.
1. Make sure the Variable Speed Potentiometer is connected properly. Refer to the configuration section for proper
setup. Verify, through the configuration software, that the MIN speed setting is less than the MAX speed setting.
2. Be sure the proper number of flywheel teeth are set.
1. The overspeed may be set is too low. Recheck the overspeed setting.
2. The SDG is not tuned properly for the application. Try retuning the SDG.
12.0 Specifications
Input/Output Parameters
Performance Supply . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 24 VDC Battery Systems (6.5VDC to 33VDC)
Isochronous Operation/Steady State Stability .................................± 0.25% Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Negative Ground (Case Isolated)
Speed Range/Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400-10KHz Ground Power Consumption . . . . . 70 mA max. continuous plus actuator current
Speed Drift w/ Temp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . < ± 1% Max. Actuator Current . . . . . . . . . . . . . . . . . . Max 10 Amp cont. [@25°C (77°F) Inductive]
Idle Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . .. . . . . . . . . . .Full Range Speed Sensor Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5-120 VRMS
Droop Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17% Regulation Load Share/Synchronizer Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-10VDC
Speed Trim Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ± 5% of Rated Speed Discrete Output . . . . . . . . . . . . . . . . . . . . . . . . . . Supply up to 25m rated 20mA@12Vdc
* Maximum RPM is based on the Flywheel Teeth. RPM= Frequency x 60/Flywheel Teeth. Maximum Frequency is 10,000Hz.
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