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This section provides information on the ESM speed governing system for variable speed applications, fixed speed applications, and synchronizer control.

VARIABLE SPEED APPLICATIONS

When operating an engine for variable speed applica-tions, user connections determine the rpm setpoint.

When the Remote Speed Select input signal is high (8.6 – 36 volts), the “Remote RPM” field on the [F4] Governor Panel is green and signals the user that it is ON. The speed setpoint is varied with either a 4 – 20 mA or a 0.875 – 4.0 volt input (ESP displays this value in mA only).

If an out-of-range speed setpoint is detected or if the wire that enables remote rpm operation fails, the speed setpoint will default to the low/high idle values.

The “Idle” field on the [F4] Governor Panel indicates whether the LOW or HIGH signal is active. The idle speeds must be set to a safe rpm.

ESP PROGRAMMING

The following fields on the [F4] Governor Panel should be reviewed to make sure they are correctly pro-grammed for variable speed application:

• “Load Inertia”: This field must be programmed by the operator for proper engine operation. See “Pro-gramming Load Inertia” on page 3.10-8 for program-ming information.

• “High Idle”: This field allows the user to program the high idle rpm. Although customer connections determine the rpm setpoint in variable speed appli-cations, the high idle setting must be programmed to a “safe” value in case an out-of-range speed set-point is detected or if the wire that enables remote rpm operation fails. The high idle rpm can be pro-grammed from 800 – 2200 rpm (not to exceed a preprogrammed maximum speed). Internal calibra-tions prevent the engine from running faster than rated speed +10%. See “Basic Programming in ESP” on page 3.10-5 if this field requires program-ming.

• “Low Idle” and “Low Idle Adjust”: These fields allow the user to view and program the low idle rpm setting. Although customer connections determine the rpm setpoint in variable speed applications, the low idle setting must be programmed to a “safe”

value in case an out-of-range speed setpoint is detected or if the wire that enables remote rpm operation fails. The teal (blue-green) “Low Idle RPM” field displays the actual programmed low idle rpm setting. The dark blue “Low Idle Adj” field allows the user to adjust the actual setting by entering a value from -50 to +100 rpm. When an adjustment is entered, the actual “Low Idle RPM” is updated to reflect the adjustment. (NOTE: The low idle rpm cannot be set higher than the high idle rpm.) See

“Basic Programming in ESP” on page 3.10-5 if low idle requires programming.

• “Droop”: This field allows the user to adjust the percent of droop. Droop allows steady state speed to drop as load is applied. Droop is expressed as a percentage of normal average speed. Droop can be programmed from 0 to 5%. See “Basic Program-ming in ESP” on page 3.10-5 if this field requires programming.

• “Auto Actuator Calibration”: It is recommended that ESP be programmed to perform an automatic throttle actuator calibration on normal shutdown.

See “Actuator Calibration” on page 3.10-13 for pro-gramming information.

FIXED SPEED APPLICATIONS

There are two fixed speeds available: low idle and high idle.

Low idle speed is the default, and high idle is obtained by connecting a digital input on the ECU to +24 VDC nominal. When the voltage signal goes high (8.6 – 36 volts), high idle speed is active. Low idle speed is preset for each engine family, but by using ESP the low idle speed can be offset lower or higher than the preset value. High idle speed is also adjustable using ESP, but is constrained to be higher than low idle speed and no higher than the maximum rated speed of the engine.

The following fields on the [F4] Governor Panel should be reviewed to make sure they are correctly pro-grammed for fixed speed application.

• “Load Inertia”: This field must be programmed by the operator for proper engine operation. See “Pro-gramming Load Inertia” on page 3.10-8 for program-ming information.

• “High Idle”: This field allows the user to program the high idle rpm. The high idle setting is used when the rated speed/idle speed digital input is high (8.6 – 36 volts) and the “Remote RPM” field is OFF. The high idle rpm can be programmed from 800 to 2200 rpm (not to exceed a preprogrammed maximum speed). Internal calibrations prevent the engine from running faster than rated speed +10%, See “Basic Programming in ESP” on page 3.10-5 if high idle requires programming.

• “Low Idle” and “Low Idle Adjust”: These fields allow the user to view and program the low idle rpm setting. The low idle setting is used when the rated speed/idle speed digital input is low (less than 3.3 volts) and the “Remote RPM” field is OFF. The teal (blue-green) “Low Idle RPM” field displays the actual programmed low idle rpm setting. The dark blue “Low Idle Adj” field allows the user to adjust the actual setting by entering a value from -50 to +100 rpm. When an adjustment is entered, the actual “Low Idle RPM” is updated to reflect the adjustment. (NOTE: The low idle rpm cannot be set higher than the high idle rpm.) See “Basic Program-ming in ESP” on page 3.10-5 if low idle requires pro-gramming.

• “Droop”: This field allows the user to adjust the percent of droop. Droop allows steady state speed to drop as load is applied. Droop is expressed as a percentage of normal average speed. Droop can be programmed from 0 to 5%. See “Basic Program-ming in ESP” on page 3.10-5 if this field requires programming.

ESP PROGRAMMING

• “Auto Actuator Calibration”: It is recommended that ESP be programmed to perform an automatic actuator calibration on normal shutdown. See “Actu-ator Calibration” on page 3.10-13 for programming information.

FEEDFORWARD CONTROL (LOAD COMING) Feedforward control is used to improve engine response to large loads. One example of how this fea-ture can be used would be in stand-alone electric power generation applications where the engine is supplying variable loads such as lights, miscellaneous small loads, and one large electric motor.

For example, the contactor for a large load could be routed to a PLC so that a request to add the load would go through the PLC. When the PLC received the request to add the load, it first would set the large load coming digital input on the ECU high for 0.5 seconds and then 1 second later actually close the contactor to add the load. This would give the ESM system a 1 second head start to open the throttle, even before the load was applied and the engine speed dropped. (Times used are examples only.) The behavior of the large load coming digital input can be customized through “trial and error” with ESP. The percent of rated load of the electric motor is set in the

“Forward Torque” field on the [F4] Governor Panel.

The Forward Delay is the lag time of the ESM system from receipt of the Load Coming signal until action is taken. As the LRG LOAD digital input goes high (8.6 – 36 volts), the engine speed should go above setpoint rpm for approximately 1 second before the load is applied. Typically the “Forward Torque” field is set to 125% and “Forward Delay” is programmed to optimize the system’s behavior.

The following fields on the [F4] Governor Panel should be reviewed to make sure they are correctly pro-grammed for Feedforward Control.

• “Forward Torque”: This field allows the user to program the forward torque amount of load coming.

When the load coming signal goes high, and after the forward delay timer has expired, the throttle opens by the programmed torque percent. The for-ward torque can be programmed from 0 to 125%.

See “Basic Programming in ESP” on page 3.10-5 if this field requires programming.

• “Forward Delay”: This field allows the user to pro-gram the forward delay timer of load coming. When the load coming signal goes high, the forward delay must expire before the throttle opens to the pro-grammed torque percent. Units are in seconds. The forward delay can be programmed from 0 to 60 seconds. See “Basic Programming in ESP”

on page 3.10-5 if this field requires programming.

SYNCHRONIZER CONTROL (ALTERNATE DYNAMICS)

Synchronizer control or alternate dynamics are gover-nor dynamics that can be used to rapidly synchronize an engine to the electric power grid. These lower gain values can also be used to minimize actuator move-ment when the engine is synchronized to the grid and fully loaded to maximize actuator life.

Raising a high digital input (8.6 – 36 volts) to the ECU, puts the ESM system’s governor in synchronizer con-trol. The user can program a small speed offset (“Sync RPM” field) to aid in synchronization.

The “Sync RPM” field must be adjusted so that the actual engine speed setpoint is approximately 0.2%

higher than synchronous speed. The additional rpm programmed in this field is added to the setpoint rpm when the “Alternate Dynamics” field is green and sig-nals it is ON. For example, if the grid frequency is 60 Hz (1800 rpm), the “High Idle” field is programmed so that the engine speed setpoint is 0.002 times 1800 rpm which is 1804 rpm.

This ensures that the electric phasing of the grid and the engine are different so that the phases will slide past each other. When an external synchronizer deter-mines that the voltage and phase of the generator match the grid, the breaker is closed. The load of the engine can now be controlled by an external load con-trol.

NOTE: When an error exists between the “Engine Speed” field and the “Eng Setpoint RPM” field, a proportional synchronous gain calibrated by Waukesha Engine is multiplied to the speed error. The gain is multiplied to increase or decrease throttle response to correct the speed error. The “Proportion Gain Adj” field allows fine-tuning for best throttle response but is typically not programmed.

The following field on the [F4] Governor Panel should be reviewed to make sure it is correctly programmed for Synchronizer Control.

• “Sync RPM”: This field allows the user to program a synchronous rpm to allow easier synchronization to the electric grid. The additional rpm programmed in this field is added to the engine setpoint rpm if the

“Alt Dynamics” field is ON. The synchronous rpm can be programmed from 0 to 64 rpm. See “Basic Programming in ESP” on page 3.10-5 if this field requires programming.

ESP PROGRAMMING