EG1065X

Generator Electronic Governor Controller

Operation Manual

Compatible with Barber Colman* Dyn1-1065X series

* Use for reference purpose only and not a genuine Barber Colman product.

Headquarters : No.3, Lane 201, Chien Fu ST., Chyan Jenn Dist., Kaohsiung, TAIWAN
Tel : + 886-7-8121771 Fax : + 886-7-8121775 URL : http://www.kutai.com.tw
 1. SPECIFICATIONS
1.1 Electronic Specifications
Operating Voltage Remote Speed Adjustment

12 or 24 VDC ±20% Select by DIP Switch 1. Connect 5KΩ potentiometer to terminal #9.
Adjustable range is approximately 5% at 1800
Output Current RPM.

Quiescent: 80 mA, Stall: 15 A 2. Connect 5KΩ potentiometer through resistor R

to terminal #8 Reducing the value of R increases
Power Input the remote adjustable speed range.
Voltage 12 or 24 VDC ±20%
Current Rated above maximum actuator stall Mechanical Vibration
current
1G @ 18 ~ 30 Hz, 2.5G @ 48 ~ 70 Hz
Temp. Stability
Relative Humidity
Better than ± 0.5% between -40 ~ 75℃
< 95%
Speed Band
Operating Temperature
± 0.25 % at steady state
-40 ~ 85℃
Dimensions
Storage Temperature
147mm L * 114mm W * 48.6mm H
-40 ~ 85℃
Weight

860g ± 2%

1.2 Compatible Products

Barber Colman P/N Speed Input Signal Frequency*

DYN1-10652-000-0-12/24 250 ~ 1200 Hz
DYN1-10653-000-0-12/24 1200 ~ 2500 Hz
DYN1-10654-000-0-12/24 2500 ~ 5000 Hz
DYN1-10656-000-0-12/24 5000 ~ 9500 Hz

*Speed Input Signal Frequency

Engine RPM × Number of Fly Wheel Gear Teeth
Speed Input Signal Frequency (Hz) =
60 seconds

Change Switch 4~7 for the correct Speed Input Signal Frequency range generated by the magnetic pickup at
the maximum engine operated (RPM) speed.

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2 EG1065X
2. FUNCTIONS 2.4 DROOP Operation
2.1 EG1065X—Electronic Controller Clockwise increases the droop. Droop operation is
obtained by setting the droop potentiometer.
EG1065X is the information processing unit of the
governor assembly. A droop potentiometer setting of 10 o'clock will give
about 4% droop, no load to full load when the pickup
It contains electronic components which process the frequency is 4260 Hz and actuator shaft rotation is
input signal from the magnetic pickup and control approximately 30 degrees from no load to full load.
the engine to the desired speed / RPM set into Lower pickup frequency or smaller shaft rotation
EG1065X. results in less droop for the system.
Electronic adjustments are available on EG1065X The amount of droop for a given setting depends on
for field adjusting the unit as necessary. the magnetic pickup frequency and no load to full
The governor system receives its power from a load actuator shaft rotation.
battery or an AC to DC power supply supplying 12
or 24 VDC ±20% to match the governor voltage. The
average operating current consumption is 2.5 to 3.5 No load
Engine RPM
amperes and the highest consumption is 14.75
Adjustadle
amperes during engine start-up or during a large Desired
load change. Engine RPM

2.2 Component Location Engine

RPM
1. EG1065X, the controller, is off-mounted or
installed in the engine control panel or cabinet.
2. The actuator of the governor assembly is Figure 2
mounted on the engine next to the fuel system.
0% % of Engine Load 100%
3. The magnetic pickup is normally mounted in the
flywheel housing in such a way that it can count
the teeth on the starter ring gear.
2.5 Remote Speed Adjustment
2.3 Isochronous Operation
A suitable remote speed selector can adjust engine
Isochronous operation is obtained by setting droop RPM from up to 90 meters (300 ft.) from the engine.
potentiometer fully counterclockwise. See Section 5, the potentiometer can be connected
EG1065X is all electric, and it is normally operated for a narrow (fine) or wide speed range control.
in the isochronous mode; i.e., engine RPM is
constant (±0.25%) under steady state load 3. INSTALLATION
conditions, up to the engine's maximum capability,
regardless of load on the engine. 3.1 Mount EG1065X in the control panel.
3.2 Connect the wiring as shown in Section
5 or according to other particular wiring
Desired
Engine RPM diagram.
3.3 Proper Procedures for Setting Switches
SW1 and SW2.
Engine
RPM lsochronous EG1065X has two response ranges for matching
Operation Mode
either the diesel or gas engine dynamics.
• Set SW1 to the OFF position for diesel engine
applications.
Engine Load 100%
• Set SW1 to the ON position for gas/gasoline
Figure 1
engine applications.
• Set SW2 to OFF, this level is nominally 6.3
amperes for actuators with lower current level.
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EG1065X 3
• Set SW2 to ON, this level is nominally 7.3 • For DROOP operation, set DROOP potentiometer
amperes for actuators with lower current level. clockwise to obtain desired amount of DROOP
from no-load to full load. Turning potentiometer
Top View

：
clockwise increases DROOP.
O
N

NOTE
ON OFF ON OFF
O
F
F
Side View Side View If the full 35° rotation of the actuator shaft is
"on" "off "
used and the linkage adjusted to use only the
1 2 active fuel range, the maximum obtainable
DROOP would be approximately 12% at full
The drawings above should clarify any confusion
load.
about switch settings. The easiest way to set the
switches is to apply pressure with a small pointed 4. If a remote speed potentiometer is used for
object until the switch clicks into position. narrow range, set it to mid-range. If the remote
speed potentiometer is connected to terminals 6,
SW1 in the above drawing is in “ON” position, and
7 and 9, a resistor "R" in the wiper is not needed.
SW2 in the above drawing is in “OFF” position.
This will provide approximately a 5%
CAUTION!! adjustable speed range.
As a safety measure, the engine should be 5. Start the engine.
equipped with and independent overspeed
shutdown device in the event of failure which • Adjust the controller speed potentiometer until
may render the governor inoperative. the engine is operating at the desired engine

：
RPM. Clockwise increases engine RPM.
NOTE • If the governor system is unstable, slightly reduce

：
For some diesel engines, better operation may the GAIN setting.
be obtained by placing SW1 in “ON” position. If NOTE
difficulty experience in “OFF” position, try SW1 Except for the speed adjustment, the
ON and recalibrate. potentiometers have internal stops at the 0 and
4. CALIBRATION OF DYN1-1065X 100% positions.
6. With the engine unloaded, finalize the settings, I
4.1 Connection Information and GAIN adjustments as follows:
1. When using an ILS unit, the remote speed (1) Turn the GAIN adjustment clockwise slowly until
potentiometer may be left connected to the the actuator lever oscillates. (One may need to
controller as shown in Section 5. disturb the actuator lever to cause oscillation.)
2. When an ILS unit is used, connect 3-wire (2) Reduce the GAIN adjustment slowly
shielded cable to terminals 6, 7 and 8. Connect counterclockwise until the lever is stable. Upset
drain shield wire to terminal 10 at EG1065X only. the lever by hand..
Other end of drain shield wire is to be cut off and
taped. (3) If the lever oscillates 3 to 5 diminishing
oscillations and stops, the setting is correct
4.2 Calibrations and Adjustments (4) If system performance to load changes is
1. See Section 5 for a reference guide before satisfactory, omit step (5), (6) & (7)
making any adjustments of the potentiometers, (5) Reduce the GAIN setting counterclockwise one
DROOP, I, GAIN and SPEED. division. Next, turn the “I” adjustment fully
2. Power OFF - engine not operating. clockwise while observing the actuator lever.

3. Initial potentiometer settings: (6) If the lever does not become unstable, upset it by
hand. When the lever slowly oscillates, turn the
• Set the “I” adjustment three divisions from zero adjustment counterclockwise slowly until the
and the GAIN at the second division from zero. lever is stable.
• For isochronous operation, set DROOP (7) Upset the lever again; it should oscillate 3 to 5
counterclockwise to minimum position as shown times and then become stable for optimum
in paragraphs 3.5 and 3.6. response.
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4 EG1065X
5. TYPICAL WIRING DIAGRAM & CONTROLLER INSTALLATION DIMENSIONS

KUTAI
ELECTRONICS 1234567
SW I
SW1-OFF-DIESEL
SW1-ON -GAS
SW2-OFF-8000 ACT
SW2-ON -8200,8400 ACT
SW3-ON -12V OFF-24V DROOP

SW4-ON -10652

SW5-ON -10653
GAIN
SW6-ON -10654
SW7-ON -10656 REMOTE
1 23 45 67 SPEED POT INC
SW _ SPEED
+

_
TP1 TP2 8V 4V ILS ~
ACT
1 2 3 4 5 6 7 8 9 10 MPU 11
Red

Black

Black

Cadle C Cable A
Red

Red

Cable B
Wnite
Black

_
+

DC Power R
Magnetic
Pickup

CCW
5K
Cadle C
CW

Actuator

DIP Switch Description

Failsafe SW1 OFF for Diesel Engine ON for Gas Engine
TP1 TP2
SW2 OFF for DYNA8000 actuator
ON for DYNA8200 / 8400 actuator
1 2 3 4 5 6 7 8 9 10 11
SW3 OFF for 24V I/O, ON for 12V I/O
ILS

Chassls Bik Wht SW4 ON* compatible with DYN1-10652

+8V +4V Exterral Gnd
Screw
Speed
Adjust
SW5 ON* compatible with DYN1-10653
Chassls Magnenic Pick-up
Battery Actuator Gnd
Screw SW6 ON* compatible with DYN1-10654
SW7 ON* compatible with DYN1-10656
*The 5K remote speed potentiometer can be wired *When one of the SW4~7 is ON, set others of SW4~7 OFF
two different ways:
Governor Controls
1. Connect 5KΩ potentiometer to terminal #9.
Adjustable range is approximately 5% at 1800 DROOP Droop rate Adjustment
RPM. GAIN MPU Output Gain Adjustment
2. Connect 5KΩ potentiometer through resistor R to I Engine Stability Adjustment
terminal #8 Reducing the value of R increases
SPEED Engine Speed Adjustment
the remote adjustable speed range.
**Cable A, B, C -- should purchase a cable with a
wrapped mylar supported aluminum foil shield *** Remote speed potentiometer and 499K ohm
with a drain wire. resistor is B-C P/N (DYNS-10000)
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EG1065X 5
6. TROUBLESHOOTING
6.1 Problem: Governor Is Completely Dead 6.1.8 Measuring the resistance of each coil lead
And Actuator Lever Stays At Minimum to the actuator case should indicate an
open circuit on a low scale of the ohm
Position When Power Is Applied To
meter.
Governor.
If continuity is detected, replace the actuator.
Means of Detection
Corrective Action 6.1.9 With the DC to the governor ON and the
engine OFF, measure the DC voltage from
6.1.1 Check battery voltage at terminals 1 and 2 terminal 6 (+) to terminal 2 (–). This should
on controller. Terminal 1 is positive. be approx. 8 VDC.
Check battery connections and contacts for If 8 VDC is not present, replace the controller.
turning power ON to the controller.
6.1.10 Between terminal 7 (+) to terminal 2 (–),
6.1.2 Check for proper linkage setup. the voltage should be approx. 4 VDC.
Correct and free linkage. If 4 VDC is not present, replace the controller.
6.1.3 Magnetic pickup signal absent or too low. 6.2 Problem: Actuator Goes To Full Stroke
Measure AC voltage across terminals 10 and When Dc Power Is Turned On (Engine Is
11 while cranking the engine. Voltage should Not Operating).

：
be min. 2.5 VAC.
Means of Detection
NOTE Corrective Action
The voltmeter should have an impedance of
5000 ohms/volts or higher. Check pole tip 6.2.1 Check magnetic pickup leads for proper
gap over gear tooth. Should be 0.037 mm / shielded wire or open shield.
0.127 mm (0.015" / 0.005"). Verify and correct wiring as necessary.
6.1.4 Measure the resistance of the magnetic 6.2.2 Be sure there is no jumper between
pickup coil. This should be above 150 terminals 2 and 3.
ohms.
Verify and correct wiring as necessary.
If there is an open or shorted coil, replace the
magnetic pickup. 6.2.3 Failsafe circuit in the controller may be
damaged or defective.
6.1.5 Measure the resistance of each pin to the
metal case of the magnetic pickup. No Replace EG1065X.
continuity should be evident. 6.2.4 With DC power OFF remove leads at
If there is continuity to case, replace the actuator. Check continuity of each
magnetic pickup. terminal to case. There should be no
continuity between any terminal and case
6.1.6 DC SUPPLY OFF. Place an insulated of EG1065X.
jumper between terminals 2 and 3 (TP1 &
TP2). With DC ON, the actuator should go If continuity is detected, replace the
to full stroke. DC voltage at terminals 4 controller.
and 5 should be within 3volts of the 6.2.5 If remote speed potentiometer has been
supply. connected to terminals 6, 7 and 9 of the
If the actuator still does not move to full controller, DISCONNECT THESE LEADS.
stroke, continue with steps below. Turn DC power ON to the governor if the
6.1.7 Measure actuator coil resistance: actuator is now normal. Proceed to step 6.3.1

If actuator coil is open or shorted to case,

replace actuator.
If governor still does not operate, continue
with steps below.

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6 EG1065X
6.3 Problem: Improper Operation From 6.5 Problem: Slow, Small Amplitude
Remote Speed Potentiometer Hunting Of Speed Or Frequency
Means of Detection Means of Detection
Corrective Action Corrective Action
6.3.1 Investigate wiring to remote speed 6.5.1 Sticking or very loose linkage.
potentiometer for open or shorted circuits.
Correct Linkage.
Check wiring.
6.6 Problem: Fast Oscillation Of Governor
6.3.2 If the leads at terminals 6 and 7 to the Linkage
remote speed potentiometer are reversed,
speed control by the remote speed Means of Detection
potentiometer will be reversed. Corrective Action
Correct wiring. 6.6.1 Verify calibration settings of the
controller.
6.3.3 Lead wire to remote speed setting
potentiometer should be 3-wire shielded Readjust settings as necessary.
cable.
6.7 Problem: Engine Will Not Start --
Verify that the drain shield wire is isolated Actuator Goes To Full Fuel During
from ground at the potentiometer. Cranking
6.3.4 If terminal 7 lead to the remote speed
Means of Detection
potentiometer is open, engine speed will
go high.
Corrective Action
6.7.1 Make sure fuel is available.
Correct the wiring.
Check fuel to engine. Check for correct wiring
6.3.5 If lead 9 (wiper lead to remote
to the automatic shutdown circuits.
potentiometer) is open, there will be no
control by the remote speed potentiometer. 6.7.2 Air may be trapped in fuel line.
Verify and correct wiring. Check fuel lines for leaks.
6.3.6 If lead 6 to the clockwise terminal of the 6.7.3 Try to operate engine manually.
remote speed potentiometer is open,
speed will remain at the value set in
EG1065X.
6.4 Problem: Erratic Governor Operation
Means of Detection
Corrective Action
6.4.1 Measure DC voltage at 1 and 2 on
controller terminal strip. Normal battery
voltage should be indicated.
If nominal voltage is present, wiring is
correct.
6.4.2 Low battery voltage 20% below rated can
cause erratic operation.
Check battery and charging system.
6.4.3 RFI noise due to incorrect shielding.
Correct wiring.
6.4.4 RFI noise fed through power supply leads.
Connect power leads directly to the battery.

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EG1065X 7