INSTRUCTION MANUAL

FOR THE
1115 - 4G TYPE GOVERNOR
 FOREWORD

These instructions have been compiled to assist personnel responsible for the operation
and maintenance of equipment manufactured by Regulateurs Europa.
Care has been taken to ensure that the equipment has been accurately represented,
but it should be appreciated that, with the continued progress of design and the diversity
of application, certain items may differ in detail.
It should be noted that these instructions are issued for general information.
Whilst reserving the right to make any alteration in design which they may consider
advisable, the manufacturers absolve themselves from making any such alteration
retrospective.
In addition to the information given herein, practical advice and assistance are always
available from our Service Department.

Regulateurs Europa B.V.

PO Box 28,
9300AA Roden,
Netherlands
Tel: +31 505019888
Fax: +31 505013618
E-mail: [email protected]
 − 1115 – 4G GOVERNOR
General
The Regulateurs Europa 1100 series governor has been established as one of the
leaders in the field of prime mover speed control for the past 20 years, with many
thousands in service throughout the world.
The 4G model is specifically designed to meet the ever increasing demands of modern
prime mover controls and incorporates a number of design improvements over earlier
models.
The 1115 – 4 G governor consists of a hydraulic governor and an electronic speed
setting control module.
A stepper motor is fitted in the governor to adjust the speed setting shaft. A contact-less
position transducer, attached to the speed setting shaft, returns a feedback signal to the
control module. The control module will increase or decrease the speed setting by
operating the stepper motor until the feedback signal matches the 4- 20 mA. command
input.
In order to set-up the speed setting range versus the desired command signal the
minimum and maximum levels can be programmed into the control unit. This however,
does not require any external equipment.

Operation
Speed setting: Proportional to a 4-20 mA speed setting signal or by means
of digital Raise / Lower commands.
Hysteresis and repeatability: To within ± 0,2% of the maximum speed.
Governor speed: Drive speed range 300 – 1500 rev/min.
Speed droop: Adjustable by external dial type control from 0-160 rev./min.
for 60% of the output shaft travel.
Output work capacity: 8, 15, 25, 34 or 40 Ft/lbs, output shaft movement 50 º,
30 º or more to be used from no-load to full-load.
Note: The 40 Ft/lbs version requires an oil cooler if the drive
speed is above 1200 rev/min.
Rotation: Either clockwise or counter clockwise.
Outputshaft dimensions: 5/8” nominal diameter, serrated, either side of the governor
may be required.
Driveshaft dimensions: ¾” nominal diameter, serrated, or alternatively, 25 mm
nominal diameter, keyed.

1
 M602901
− 4-20 mA SPEED SETTING CONTROL MODULE

Specification

Power supply: 24 Vdc +/-20%, 1,75 A.

Ambient temperature: 70º Celsius

Output: Bipolar chopper regulated four wire to drive a

stepper motor 5 Volt 1 Amp.

Command input: 4-20 mA into 240Ω galvanic isolated.

Range minimum signal level 4 – 8 mA.
Range maximum signal level 16 – 20 mA.

Feedback input: 8 – 16 mA into 200Ω or

0,7 – 3,5 V into 150 kΩ
Supply feedback transducer 10 V.

Digital inputs: 24 V into 10 kΩ

“H” status > 7,5 V.
“L” status < 5,0 V.

Functions: - Analogue or digital speed setting mode.

- Raise speed in digital mode.
- Lower speed in digital mode.
- Select fast / slow mode in digital mode.
- Minimum speed stop.
- Maximum speed stop.
- Reduced maximum analogue speed level.
- Fast run down to minimum speed level.
- The speed setting will be frozen in last position upon loss
of
the command and/or feed- back signal.
(This function can be disabled using dip-switches).
- Nine programmable signal levels to set minimum and
maximum command and feedback level and minimum and
maximum speed stop positions.

2
Analogue mode Independently adjustable raise and lower speed rates.
speed setting: Range of maximum pulse rate setting 100 p.p.s. to
1000 p.p.s.
Below 20% of maximum speed setting error the pulse rate is
proportional to error.

Dead band: Adjustable between 0 – 4% error.

Digital speed setting: If “slow” is selected adjustable from 6 to 90 p.p.s., if “fast” is

selected 30 to 400 p.p.s.

Alarm output A potential free change over contact is available for alarm
indication. It will change status in case of:
a. Power loss and/or program mal-function.
b. Loss of the command and / or feedback signal.

LED indication: a. Command signal lost.

b. Feedback signal lost.
c. Raise speed.
d. Lower speed.
e. Maximum speed stop reached.
f. Minimum speed stop reached.

Dimensions: 100 x 200 x 70 mm.

Suitable for mounting on TS32 or TS35 rail.

3
 GOVERNOR
General
Care must be taken to ensure that the platform, on which the governor is mounted, is perfectly
flat and absolutely square to the driving shaft. It is important that no side loading nor bending
movement is applied to the governor drive. Any misalignment between the drive shaft and
driving member will cause an oil leakage between the drive shaft and oil seal and in severe
cases even cause broken drive shafts.

Correct choice of drive gear ratio is most important as it is essential that the governor runs at or
near its nominal speed (1 500 Rpm) when the prime mover is at full speed, otherwise
performance will be affected. This condition is particularly important in marine applications
where a prime mover operates over a wide speed range.

The gears must be free from any imperfections; run-out of gears should not exceed
0,004 mm per cm. The governor will pick up any such errors and ‘jiggle’ of the governor terminal
(output) shaft will result. The backlash in the driving gears should be set at a minimum of 0,05
mm. Under no circumstances should this clearance exceed 0,15 mm.

Control Linkage
The linkage between the governor output shaft and the fuel-injection pump should be
designed to the following criteria:
• Correct ratio
• No backlash
• Low frictional losses
• Linearity

Correct Ratio
The geometry of the linkage should be designed so that 60 % (i.e. 300) of the output shaft
rotation is used for moving the fuel-injection pump/control valve between the ‘no load” and the
‘full load’ positions.

Backlash
Backlash should be kept to a minimum as it will create a dead band in which speed changes
may take place without correction. In addition backlash may cause instability if the governor
droop control is set to zero, (isochronous operation)

Friction
Friction in the governor linkage is undesirable and should be kept to a minimum.
The smaller the amount of work to be done by the governor, the more rapid will be its response.
It is recommended that the linkage between the governor and fuel rack is equipped with a
spring link which will be activated only when the fuel rack is jammed or blocked by the
maximum power stop of the fuel rack.

4
Linearity
The geometry of the fuel-injection pump linkage is normally arranged so, that the increase in
power from ‘no load” to “full load’ is, as near as possible, linear proportional to the movement of
the governor output lever throughout its range (from position ‘two’ to position ‘eight’). If this is
not so, i.e. if a small output movement at low load has proportionally greater effect on power
output than a similar movement at greater load settings, the governor will have the tendency to
‘hunt”.

Filling with oil

After installation the governor must be filled to the indicated oil level mark on the sight glass
fitted at the side of the governor, i.e. within the red engraved circle.
Do not overfill since this will result in foaming of the oil and therefore hunting.
A governor that is being filled for the first time or one which has just undergone repairs may
require to have the level rechecked soon after it has been started up. This is overdue to the
filling of oil passages which will lower the level. Should it be necessary to remove excess oil
from the governor due to overfilling, any one of the two drain plugs (magnetic plugs) in the base
of the unit may be used for this purpose.

Type and Grade of Oil

As a general guide the oil used in the governor should be a good quality mineral oil. It should
have good oxidation stability and should have anti-foaming and anti-deposits properties. The
use of high TBN oils (greater than 1 5) in governors is undesirable as the oil additives can
cause seal hardening. Marine engine oils for engines using gas oil or marine diesel oil are
normally satisfactory, but not those used in engines running on heavy fuel.
The Regulateurs Europa 1100 governor series has been designed to operate using a standard
SAE 30 mineral oil for most applications. However, if the ambient temperature is constantly
above 50°C, then SAE 40 is recommended.
If instability is experienced when the engine has been started from cold but disappears with the
increase in temperature, then it is advised to use of a multi-grade oil.
DO NOT use hydraulic oils, or those with a high alkaline value.

Oil level
In order to prevent any unwanted substances from entering the governor unit, it is essential to
clean the area surrounding the filler neck prior to adding oil. The governor should be at its
normal working temperature and filled through a fine mesh filter, until the level reaches the
centre of the red circle engraved in the sight-glass.

DO NOT OVERFILL as this will result in foam within the oil giving poor governor
performance.

5
Initial Starting Procedure
Check correct level of oil
Set the speed setting control to the low speed position.
If the governor has a solenoid operated shutdown mechanism energise to run ensure that the
correct voltage is supplied.
Start and run the engine unit in accordance with the manufacturer’s instructions. When the
engine is being started for the first time since refitting the governor, slight erratic governing may
be expected. This will be eliminated after a few minutes when the air trapped in the hydraulic
system has been automatically purged. Subsequent starling operations should not experience
this problem because of the unique ‘self blending’ action.

Hunting
Hunting’ is best described as a rhythmic change in speed with the amplitudes above and below
set speed. The frequency of these changes are normally around I hz.
Check the fuel-injection pump linkage for backlash or friction. Ensure that the linkage ration is
correct, i.e. that minimum 60 % of the output shaft’s total movement is used from ’no load’ to
‘full load’.
Hunting at ‘no load’ may result from defective injectors causing the engine to 8-stroke (or 4-
stroke in the case of a two stroke engine).
In a new installation or after governor overhaul, hunting may be due to air trapped in the
governor oil ways. This should purge itself after a few minutes of running.
However, if the governor continues to hunt, the following procedure may be adopted:

1. Open the restrictor screw and allow the governor to hunt over a large amplitude. If this is
not possible, stop the engine, disconnect the governor linkage and operate the governor
output manually, moving over the full travel range several times.
2. Close restrictor screw to normal setting, re-connect linkage and re-run the engine.

Closing the restrictor screw by clockwise rotation, should stabilise the governor. In a new
governor the restrictor screw is pre-set and will be between ½ to 1½ turns open.
If the possible install another governor of similar type on the same engine to ascertain results of
alternatively try the governor on a similar type of engine.

Jiggle
Jiggle is the term used for rapid oscillation of the governor output lever at a frequency too high
for the engine speed to follow. These movements are relatively small and have no noticeable
effect on speed. Jiggle usually originates in the governor drive. Check for runout, backlash and
alignment to the governor.

6
 − M602901
− 4-20 mA SPEED SETTING CONTROL MODULE

Specification

Power supply: 24 Vdc +/-20%, 1,75 A.

Ambient temperature: 70º Celsius

Output: Bipolar chopper regulated four wire to drive a

stepper motor 5 Volt 1 Amp.

Command input: 4-20 mA into 240Ω galvanic isolated.

Range minimum signal level 4 – 8 mA.
Range maximum signal level 16 – 20 mA.

Feedback input: 8 – 16 mA into 200Ω or

0,7 – 3,5 V into 150 kΩ
Supply feedback transducer 10 V.

Digital inputs: 24 V into 10 kΩ

“H” status > 7,5 V.
“L” status < 5,0 V.

Functions: - Analogue or digital speed setting mode.

- Raise speed in digital mode.
- Lower speed in digital mode.
- Select fast / slow mode in digital mode.
- Minimum speed stop.
- Maximum speed stop.
- Reduced maximum analogue speed level.
- Fast run down to minimum speed level.
- The speed setting will be frozen in last position upon loss of
the command and/or feed- back signal.
(This function can be disabled using dip-switches).
- Nine programmable signal levels to set minimum and maximum
command and feedback level and minimum and maximum
speed stop positions.

7
Analogue speed setting
mode: Independently adjustable raise and lower speed rates.
Range of maximum pulse rate setting 100 p.p.s. to 1000 p.p.s.
Below 20% of maximum speed setting error the pulse rate is
proportional to error.

Dead band: Adjustable between 0 – 4% error.

Digital speed setting: If “slow” is selected adjustable from 6 to 90 p.p.s., if “fast” is

selected 30 to 400 p.p.s.

Alarm output: A potential free change over contact is available for alarm
indication. It will change status in case of:
- Power loss and/or program mall-function.
- Loss of the command and / or feedback signal.

LED indication: -. Command signal lost.

-. Feedback signal lost.
-. Raise speed.
-. Lower speed.
-. Maximum speed stop reached.
-. Minimum speed stop reached.

Dimensions: 100 x 200 x 70 mm

Suitable for mounting on TS32 or TS35 rail.

Speed setting module M602901

8
 − Functional Description

Controller
The heart of the module is formed by a micro controller which scales the command and
feedback inputs, controls the various functions and drives the stepping motor drive circuitry.
Several parameters can be loaded into the micro controller, saved in a E-Eprom and thus
protected for power loss.
To “program” the micro controller a miniature rotary selector switch with 10 positions and a push
button switch are mounted on the board.
Position “0” of the selector switch is the normal operating mode while, if one of the other
positions is selected, the parameters can be saved into the memory by pressing a push button
switch.

For example:
The level of the command (-lever) signal at which maximum set speed must be achieved is 19.2
mA. In order to “program” this value the selector switch is set at position 2, upon which also the
“program” LED starts flashing. While the 19.2 mA. command signal is applied to the analogue
input, the push button switch is pressed and the value 19.2 mA. as being the command signal
level for maximum speed is saved into the E-Eprom. The LED stops flashing and is constant on
indicating the value has been accepted and saved.
Every time a value is loaded into a memory location, the previous value is overwritten. This can
be done an unlimited number of times.

The following memory locations are available:

Position 1 “Minimum. Command” position

The minimum value of the command signal. Usually 4 mA, however the signal
level may be within 4 – 8 mA. window

Position 2 “Maximum. Command” position

The maximum value of the command signal. Usually 20 mA, however the signal
level may be within 16 – 20 mA. window.

Position 3 “Minimum. Feedback” position

The position of feedback signal, i.e. speed setting, which must correspond to the
minimum command signal.

Position 4 “Maximum. Feedback” position.

The value of the feedback signal, i.e. speed setting, which must correspond to
the maximum command signal.

Position 5 “Minimum. Digital Feedback” position in Digital Mode.

Minimum feedback position if digital speed setting has been selected.
(Minimum speed stop in digital mode).

9
Position 6 “Maximum. Feedback” position in Digital Mode.
Maximum feedback position if digital speed setting has been selected.
(Maximum speed stop in digital mode).

Position 7 “Fast Run Down” position.

The feedback level to which the speed setting will be reduced is the input “Fast
rundown to minimum level” is energised. (Only effective in analogue mode).

Position 8 “Reduced Maximum Feedback” position.

The value of the feedback signal, i.e. speed setting, which must correspond to
maximum command signal and if digital input #7 “Reduced analogue speed
setting” is energised.

Position 9 Spare.

The diagram below indicates the relation between the memory positions for analogue speed
setting.

10
Potentiometers
Apart from the programmable settings, 10 - turn potentiometers are fitted on the board for
setting the following parameters:

P1 Pulse rate for increase speed if analogue control has been selected.
P2 Pulse rate for decrease speed if analogue control selected.
P3 Pulse rate for increase and decrease if digital and fast mode selected.
P4 Pulse rate for increase and decrease if digital and slow mode selected.
P5 Dead band between command and feedback signal in analogue mode, i.e. a small
acceptable difference between the two signals in which the stepper motor is not pulsed
up or down.
P6 Spare.
P7 Timer setting during which the speed setting is kept at “Fast run down level” after de-
energising input 8. Range 0 – 60 sec.

11
Digital Inputs
Input 1: “Select analogue / digital”
If energised the speed setting of the governor will follow the 4-20mA command
signal. If the error between command and feedback signal is less than 20%, the
pulse rate to the stepper motor will be proportional to the difference between
command and feedback signal. If this error exceeds 20% the pulse rate is limited
by the setting of potentiometer P1 for increase and by P2 for decrease speed.
If input 1 is de-energised, Digital Mode selected, the speed setting can be
changed by using the inputs 2 and 3.

Input 2: “Raise speed”

If energised; the speed setting will be increased provided:
Digital mode is selected (input 1 is not energised).
Input 6 “Maximum stop” is not energised.
The position of the feedback signal is at a lower set speed level than “saved’ in
“Program switch” position 6.

Input 3: “Lower speed”

If energised; the speed setting will be decreased provided:
Digital mode is selected (input 1 is not energised).
Input 5 “Minimum stop” is not energised.
The position of the feedback signal is above the set speed level “saved’ in
“Program switch” position 5.

Input 4: “Select fast / slow digital”

If energised; the pulse rate in digital mode for both in- and decrease is set by
potentiometer P3, range 30 - 400 Hz (fast mode).
If de-energised the pulse rate in digital mode for both in- and decrease is set by
potentiometer P4, range 6 – 90 Hz (slow mode).

Input 5: “Minimum speed stop”

If energised; decreasing the speed setting in any mode is inhibited.

Input 6: ”Maximum speed stop”

If energised; increasing the speed setting in any mode is inhibited.

Input 7: “Reduced analogue speed setting”

If energised and if analogue speed setting is selected, the maximum set speed
level is equal to the level ”saved” in “Program switch” position 8. If the speed
setting is above this level at the moment the input is energised it will be reduced
until equal to the value saved at position 8 “Reduced max. pos”.

12
Input 8: “Fast rundown to minimum speed setting”
If energised and if analogue speed setting has been selected the speed setting
will be ramped down until the feedback signal reaches the value equal to the one
saved in “Program switch” position 7.
If de-energised the speed setting will first remain at the “Fast run down level” until
a timer has elapsed. The timer can be set by means of potentiometer P6, The
range is 0 – 60 seconds (fully anti-clockwise is 0 seconds). While the timer is
expiring the “Program LED” will be steady on. If the timer has elapsed the speed
setting will return to the corresponding command level setting if analogue mode
has been selected or, if digital mode has been selected, remain at the same
position until a raise or lower command is given.

Input 9: Spare.

Dip switches:
Four dip-switches are fitted on the board with the following functions:

SW1: Selects a current or voltage feedback signal.

ON
If the feedback signal is a current signal. (Default)
OFF
If the feedback signal is a voltage signal. (Special applications only)

SW2: Selects a normal or reverse acting feedback signal.

The feedback transducer, which senses the position of the speed setting shaft, can be
fitted to the speed setting mechanism in different ways. This implements that,
depending at how the transducer is fitted, the feedback signal will either increase with
an increasing speed setting or just opposite, decrease with increasing speed setting.
The type of feedback signal, normal or reverse can be selected with dip-switch 2. The
“mode” is also indicated on the serial plate of the governor.
ON
The feedback signal decreases if the speed setting is increased. Reverse feedback,
mode 3.
OFF
The feedback signal increases if the speed setting is increased. Normal feedback,
mode 2.

13
SW3: Selects if the analogue input for the command signal is to be monitored for absence of
the command signal (input < 2 mA.). If for instance , the unit is used for digital set
speed adjustment only and no analogue command signal is connected to the module,
this function can be disabled.
ON
The analogue input is monitored for signal failure. If the input drops below 2 mA. the
position of the speed setting is frozen, the red LED “CMD Lost” will be on and the alarm
output relay will de-energised.
OFF
The analogue input is not monitored for signal failure. If the input drops below 2 mA.
the position of the speed setting will be driven to minimum speed. There will be no
alarm output.

SW4: Selects if the analogue input for the feedback signal is to be monitored for absence of
the feedback signal (input < 2 mA.). If the unit is used for digital adjustment only and no
feedback signal is available, for instance to replace previous design stepper motor
drive boards, this function can be disabled.
ON
The feedback input is monitored for signal failure. If the input drops below 2 mA. the
position of the speed setting is frozen, the red LED “FBD Lost” will be on and the alarm
output relay will de-energised.
OFF
The analogue input is not monitored for signal failure. If the input drops below 2 mA.,
while analogue speed setting has been selected, the speed setting will be driven to
maximum speed. There will be no alarm output.

14
 INSTALLATION
Refer to connection diagram ES6000.

• The Control Unit must be located in a suitable enclosure.

• The cable between control unit and governor must be shielded, the shield connected to
earth at one cable end only.
• The cable length between control unit and governor must not exceed 25 m.

Although the unit is pre-set at the factory, the settings can be changed on site.
If new settings are to be loaded into the memory of the control unit first disconnect terminals 3,
4,5 and 6 at the control unit.
The feedback signal may be checked by connecting a mAmp. meter in series with terminal 10.
The signal will be 5 - 18 mA., depending of the position of the speed setting.

Start the engine and manually turn the speed setting (while terminals 3, 4, 5 and 6 are
disconnected) until the engine is at the correct speed
On the Control Unit turn the rotary selector switch to the position corresponding with the speed
setting that is to be changed (the red LED will start flashing) and press the push button switch.
The LED stops flashing and is constant on indicating the value has been accepted and saved.
Next turn the selector switch to position “0” and re-connect terminal 3 – 6.
To change the ramp rate of the speed setting of the governor turn the corresponding
potentiometer clockwise for faster and anti-clockwise for slower.

Note:
For most applications the following can be done:
Disconnect terminal 3 – 6.
Manually adjust the speed of the engine to minimum speed.
Set the rotary switch on position 3, press on the push button, the LED stops blinking.
Set the switch to position 5, press on the push button, the LED stops blinking.
Set the switch on position 7 and press on the push button, the LED stops blinking.
Next, increase the speed of the engine to nominal speed and load this into position 4, 6 and 8.
Re-connect terminal 3 – 6.

Note:
Under normal conditions when the Control Unit is powered on and connected to the governor
there is “holding torque” applied to the steppermotor. Under these circumstances it is normal
that it is difficult to manually adjust the speed setting.
The feedback transducer is NOT a potentiometer, but a position sensor with current output
signal.
Always observe that, if the 10 or 14 pole connector is disconnected, the speed setting
mechanism can be moved easily and that it is not blocked by the mechanical speed stops at the
side of the governor.
If the governor is set with droop make sure that the droop effect from no load to full load is taken
in account while making the speed settings.

15
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STANDARD DIN

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RAIL MOUNTING

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REGULATEURS EUROPA