IGA225

Integrated Governor & Actuator

1 INTRODUCTION 3 INSTALLATION
GAC’s IGA225 integrated digital governor and actuator is designed to regulate
engine speed on diesel and gaseous fueled engines. The IGA is a suitable up-
grade for any mechanical governor system that needs flexibility, precision, or Vertical orientation allows for the
draining of fluids in moist environ-
accurate control of governed speed. The IGA is designed for industrial engine ments. Do not install with the connec-
applications from generator sets, and mechanical drives, to pumps or compres- tor facing upwards.
sors.
YES NO

Avoid Extreme Heat

Dimensions:
Internet Connection Smart VU Software [mm]
Computer
www.governors-america.com in
134
5.27
A computer and an internet connection will be required to download and then 26
1.03 117
run GAC’s SmartVU software.
A 4.63 A

2 SPECIFICATIONS Section View

Below

PERFORMANCE
Available Torque 105
2.2 ft-lb max (2.7 Nm) 4.15
(Without Return Spring)
Max Angular Travel 25° ±1° CW/CCW
153
Isochronous Operation ± 0.25% 6.01

Speed Range / Governor 400 - 10 KHz

Idle Adjust Full Range
Droop Range 1 - 5% regulation 9
.34
Speed Trim Programmable 0 -100%, (default = 5%) D.62 SPOTFACE
2 PLACES
COMPLIANCE / STANDARDS
Agency CE and RoHS Requirements
Communications RS-232-C, SAE J1939 134
5.27
PHYSICAL 117
Dimension See Section 3 “Installation” 4.63

Weight 8.63 lb (3.91 kg)

Mounting Electrical Connector At The Top Preferred

ENVIRONMENTAL
Ambient Temperature -40° to 85°C (-40 to 180°F) 9 104
.34 4.10
Relative Humidity Up to 95% D.62 SPOTFACE 90
2 PLACES 3.53
All Surface Finishes Fungus Proof and Corrosion Resistant

INPUT / OUTPUT
Supply 12-24 VDC Battery Systems (6.5 to 33 VDC)
Polarity Negative Ground (Case Isolated)
SECTION A-A
Power Consumption 70mA max. Continuous Plus Actuator Current 26
1.03
Speed Sensor Signal 1.0 -120 VRMS
Load Share / Synchronizer Input 0 -10 VDC ( 5V nominal, reversed, 107Hz / V Max)
Reverse Power Protection Yes
Transient Voltage Protection 60V
Overspeed Rated to 2A DC
119
RELIABILITY 4.69
Vibration 7G, 20-100 Hz
Shock 20G Peak
Testing 100% Functional Testing

IGA225 Integrated Governor Actuator 7.15 PIB 2250 A

1 © 2015 Copyright All Rights Reserved
 IMPORTANT
Linkage arrangement of any actuator system is always im-
portant. High quality rod end bearings should be used. Rod 4 WIRING
end bearings that have high friction can cause instability and
require servicing. Levers and linkage should be sturdy yet low in mass for the 14 10 14 pin AMPSEAL requires GAC mating connector
fastest speed of response. Arrangement of the linkage for actuation of the en- 9 6
EC1502 or cable harness CH1520
5 1
gine fuel control is an important application consideration. For proportional ac-
tuators to operate with linear control systems, it is important to obtain a linear
relationship between actuator stroke and fuel delivery. The linkage configuration * Keep reading for diagrams and/or additional notes
for diesel fuel systems is typically as illustrated in Diagram 1. The lever on the PIN DEFINITION GAUGE NOTES
actuator should be nearly parallel to the pump lever at the mid fuel position for
linear fuel control. 1 - - -

2 - - -
DIAGRAM 1 FUEL LEVER AT MID FUEL POSITION
3 Magnetic Pickup (+) #20 AWG * Ground to Terminal 10
* 0 - 10 V Range, 5V Nominal,
4 Aux Input #20 AWG
Reverse Polarity
5 Speed Select A #20 AWG * Ground to Enable
6 Speed Select B #20 AWG * Ground to Enable
7 RS-232 Enable #20 AWG * Connect to ground to enable RS232
8 Overspeed Output #16 AWG * 2A Max
* 5K Ω Resistive or
9 Variable Speed Input #20 AWG
0-5 VDC selectable in software
Ground / Battery Pwr (-) Battery Twisted Pair to Magnetic
10 #16 AWG
/ Magnetic Pickup (-) Speed Pickup
For proportional actuators to operate with non-linear systems, it is important A 15 amp fuse must be installed in
to obtain a non-linear relationship between actuator stroke and fuel delivery. 11 Battery Power (+) #16 AWG the positive battery lead to protect
Carbureted, PT Pumps (CUMMINS), or other non-linear fuel systems require against any overload or short circuit
a non-linear fuel linkage configuration as illustrated in Diagram 2. A non-linear * 120 Ohm Resistor Built-In, Jumper
fuel system results when more engine power is developed for a given stroke at 12 CAN Termination #20 AWG
to CAN L #13
positions of low fuel settings rather than at high fuel settings. In this case the
13 (CAN L / RS232 TX) #20 AWG
levers should be parallel at full load. * Twist Wires 14 turns per foot.
14 (CAN H / RS232 RX) #20 AWG
DIAGRAM 2 FUEL LEVER AT FULL FUEL POSITION RECOMMENDATIONS
1. Shielded cable should be used for all external connections to the IGA
control. One end of each shield, including the speed sensor shield,
should be grounded to a single point on the IGA case.

Fuse
15 AMP Max
IGA Mating Connector Basic Wiring
- Battery +
12/24 VDC
14 13 12 11 10

9 8 7 6

5 4 3 2 1
In general, the linkage should be adjusted so that the fuel control lever minimum
and maximum fuel stops are used rather than the actuator internal mechanical +
stops. The actuator should be adjusted so that it operates over at least one half Magnetic Speed
Pick-Up -
(12 degrees) of its available travel.

PIN 3 Magnetic Speed Pickup

• Wires must be twisted and/or shielded for their entire length

(14 turns per foot)
• Gap between speed sensor and gear teeth should not be smaller
than 0.02 in. (.51mm)
• Speed sensor voltage should be at least 1VAC RMS during crank

If the IGA225 detects no input from the magnetic pickup,

WARNING
the IGA will be set to 0V and the speed set to 0 RPM. After
the IGA has detected loss of magnetic pickup, the LED #1 will flash red and the
system must be reset. To reset the IGA, DC power must be cycled.

IGA225 Integrated Governor Actuator 7.15 PIB 2250 A

2 © 2015 Copyright All Rights Reserved
 PIN 4 Accessory Input
5 LED DEFINITIONS
The Aux Terminal accepts signals from:
LED # COLOR DEFINITION
• GAC Accessories connect directly to this terminal
• Auto Synchronizers FLASHING Controller is powered and the microprocessor is initial-
1 GREEN ized.
• Load Sharing Units Aux IGA225
1 FLASHING RED Controller has tripped overspeed.
• Other Governing Accessories 4
1 SOLID GREEN Controller has achieved the chosen running speed.

Will pulse when the controller has not reached running

2 FLASHING RED speed.
Case
ALTERNATING Variable speed enabled and controller has achieved the
2 RED & GREEN chosen running speed.
PIN 5 & 6 Speed Select SPEED Select 1 is enabled and controller has achieved
2 SOLID GREEN the chosen running speed.
Open Terminals Grounded Terminals
WIRING COMBINATIONS 2 SOLID RED SPEED Select 2 is enabled and controller has achieved
5 5 the chosen running speed.
PIN 5 PIN 6 Speed Mode
IGA225

IGA225

SPEED Select 1 & 2 is enabled and controller has

6 6
Open Open Variable Speed (or Fixed Speed) 2 SOLID AMBER achieved the chosen running speed.
10 10 Ground Open Fixed Speed 1
Open Ground Fixed Speed 2
Ground Ground Fixed Speed 3 - Idle LED1
LED2

PIN 8 Overspeed Output

If the IGA225 detects the engine speed has reached the

WARNING
value specified by OVERSPEED parameter (Main Menu),
the IGA225 will command the engine speed to 0 RPM and the actuator output to
0V. After the IGA has detected an overspeed, LED #1 will flash and the system
must be reset. To reset the IGA, DC power must be cycled.
6 SMARTVU
PIN 9 Variable Speed
Pin 7 on the IGA must be grounded for communication to
Variable speed is enabled when Terminals 5 and 6 are not grounded. See “WIRING COM-
NOTE
SmartVU.
BINATIONS”. A 5K potentiometer or a 0-5 VDC signal can be connected to terminal 9.
The IGA225 is programmed using GAC’s SmartVU software. The SmartVU
Variable Speed can be used as a fixed speed setting if both SPEED installation file and instructions can be found at:
NOTE
MIN and SPEED MAX parameters are set to the same RPM and
no potentiometer is connected. See section 10 for Variable Speed Setup Pro-
cedure.
http://www.governors-america.com/Downloads/SmartVU
0 -5 VDC Signal
0 -5 VDC Signal 5K Potentiometer
5K Potentiometer

9 9 9 9
Setup Connection Menu
IGA225

IGA225

10 10 If your PC only has a USB and no serial port, you need an

IMPORTANT
adapter. You also need to find which COM port will commu-
10 10 nicate with the IGA. A tutorial on how to find your COM port can be found here:
http://www.governors-america.com/downloads/software/PIB_COMPORT.
After “EDG6000” has been properly selected from the Setup Connection Sub-
menu and SmartVU recognizes the device, parameters can then be adjusted
using the Main Menu and the Governor Advanced Settings Menu.
PIN 13 & 14 CAN or RS232 The IGA225 uses the EDG6000 governor hardware and SmartVU
NOTE
settings.
If CAN termination is required, tie pin 12 to pin 14. See CAN WIRING below.

CAN WIRING RS232 WIRING

CAN RS232
IGA225 IGA225
120 Ohm
10 7 13 14
7 12 13 14 Tx Rx
Open

Case
5 4 3 2 1

CAN L CAN H 9 8 7 6

= optional CAN termination

DB9 Connector

1. RS232 Enable to ground in order to commuicate (Pin 7).

IMPORTANT
2. On CANbus there is only engine speed output. It can not
take speed requests. The ECU ID is 26 on the CANbus
with message EEC1.
IGA225 Integrated Governor Actuator 7.15 PIB 2250 A
3 © 2015 Copyright All Rights Reserved
 Setup Connection menu is found under the “Configure” pull-down menu. 8 STARTING THE ENGINE
Crank the engine with DC power applied to the governor system. The initial
amount of power to the actuator is determined by the ACTUATOR BEGIN
POINT parameter (default is 100% open). ACTUATOR RAMP RATE will control
the rate at which fuel is increased to start the engine.

Main Menu Once the engine has been started, the linkage can be optimized by temporarily
inserting an ammeter in one of the wires between the speed control unit and the
actuator or by measuring the voltage across the actuator. Measure the actuator
current or voltage at no load and full load. The range and the starting current
or voltage are important for optimizing the linkage system. Typical values are
shown in the table following for 12 volt and 24 volt Systems.

ACTUATOR CURRENT/VOLTAGE
RANGE CHART
12 VOLTS 24 VOLTS
No Load 2.5 Amp, 4 Volts 0.5 Amps, 12 Volts
Full Load 4 Amp, 6 Volts 1.2 Amps, 18 Volts

To increase the range of the actuator voltage or current: move the linkage
to a lower hole on the actuator lever. A lower range of actuator current than sug-
gested can cause instability or poor performance.
To increase or decrease the no load current or voltage: Adjust the length of
the link between the actuator and the engine fuel control.
Smaller angles of actuator travel may improve transient performance, but will
IMPORTANT Click “Save Data to Device” to update governor’s memory. reduce available force at the fuel control lever. Allowing the actuator to operate
through at least one half (12 degrees) of its stroke will usually provide near
optimum response.

9 ADJUSTING FOR STABILITY

nce the engine is running at operating speed and at no load, the following
O
governor performance adjustment can be made to increase engine stability.

MAIN MENU

7 PRE-START PARAMETER
1.
ADJUSTMENT PROCEDURE
Increase this parameter until instability develops.
Reconfirm that the linkage is not binding and that friction
IMPORTANT 2. Then, gradually decrease this parameter until stability re-
is minimal. Before starting the engine, push the actuator to
P turns.
the full fuel position and release. It should return instantly to the no fuel position
without any binding. (GAIN) 3. Finally, decrease this parameter one increment further to
ensure stable performance.
The following parameters must be set before starting the engine:
4. If instability persists, adjust the stability parameter.
Setup & Safety 1. Follow the same adjustment procedure as the P parameter.
I
• Overspeed (STABILITY) 2. If instability persists, adjust the deadtime parameter.
• Teeth D
1. Follow the same adjustment procedure as the P parameter.
(DEADTIME)
• Ramp Up
• Ramp Down P, I, & D parameter adjustments may require minor changes after
NOTE
engine load is applied. Normally, adjustments made at no load
achieve satisfactory performance. If further performance improvements are re-
quired, refer to Section (11) GOVERNOR ADVANCED SETTINGS and Section
Starting Parameters
(12) SYSTEM TROUBLESHOOTING.
For more details on these parameters, refer to Section 11 GOVER-
NOTE
NOR ADVANCED SETTINGS.

• Crank Cutoff
• Actuator Ramp Rate
• Actuator Begin Point

For more details on these parameters, refer to Section 10 Main

NOTE
Menu Parameters

IGA225 Integrated Governor Actuator 7.15 PIB 2250 A

4 © 2015 Copyright All Rights Reserved
10 MAIN MENU PARAMETERS
Name Range
FIXED SPEED PARAMETERS
Default Definition
Remember to save. Click “Save Data to Device” to update
IMPORTANT EDG selects one of three fixed
governor’s memory.
Speed 1,2,3 0 - 9999 1500,1800,900 speeds. Fixed Speed 3 is Idle Speed
(RPM)

Idle speed must be set below operation speed but above crank
NOTE
termination (600-1200) even if it is not being used.

VARIABLE SPEED PARAMETERS

Name Range Default Definition
Speed Min 0 - 9999 1500 Minimum allowed RPM desired
Speed Max 0 - 9999 1500 Maximum allowed RPM desired

Perform the following precedure with the unit powered and the
STARTING PARAMETERS CAUTION
engine not running to set the variable speed limits. The potenti-
Name Range Default Definition ometers must be calibrated to those limits afterwards.
RPM at which EDG switches from
Crank Cutoff 100 - 500 480 Variable Speed Setup Procedure
starting to governing
Throttle position’s rate of change 1. In the “[3 - Idle Speed]” parameter under “FIXED SPEED PARAMETERS”,
Actuator Ramp Rate 0 - 100 2 from the throttle begin point to 100%, input a value 50 RPM below the desired idle speed setting.
during the start/crank cycle (% / s)
Starting position of the actuator
Actuator Begin Point 0 -100 100
during the start/crank cycle (%)

2. Navigate to the “Governor Advanced Settings” menu by clicking on the

“Options” drop-down menu and selecting “Governor Advanced Settings”.

SETUP & SAFETY

Name Range Default Definition
RPM at which to automatically shut
Overspeed Cust. Dep. 2220
off the actuator
Number of teeth on flywheel [fre-
Teeth 50-250 120 q(Hz) = (RPM/60) x (# of gear
teeth)]
3. Select/enable the check box labeled “Variable Speed Voltage”.
Allows for rapid engine speed re-
sponse with minimal overshoot
Ramp Up 0 - 9999 300
during engine start and accelera-
tion (RPM/s)
Allows for rapid engine speed re-
Ramp Down 0 - 9999 300 sponse with minimal undershoot
during engine deceleration (RPM/s)

If using a 5KΩ potentiometer, leave “Vairable Speed Voltage” un-

NOTE
checked”.

IGA225 Integrated Governor Actuator 7.15 PIB 2250 A

5 © 2015 Copyright All Rights Reserved
 4. Return to the main page. Under “VARIABLE SPEED PARAMETERS”, input the
desired idle RPM in the box labeled “Speed min” and hit the “Enter” key. 11 GOVERNOR ADVANCED SETTINGS
Governor Advanced Settings will further adjust engine stability and can be ac-
cessed through the “Options” pull-down menu on SmartVU’s Main Menu.

5. Input the desired maximum RPM in the box labeled “Speed Max” and hit the
“Enter” key.

Variable Speed Pot Calibration

1. After setting Speed min and max, set the speed input to its minimum; either 0
volts or turn the potentiometer full counter clockwise.
2. Click the button labeled “Speed Pot Calibration” and hit enter ( or click the
button labeled “Save Data to Device”).

8. Set the speed input to its maximum; either 5 volts or turn the potentiometer full
clockwise.
9. Click the button leveled “Speed Pot Calibration” and hit enter ( or click the
button labeled “Save Data to Device” )
UPDATE RATE & PID SCALE
The displayed values under “Pot min” and “Pot max” are in
NOTE
counts. When a 5k potentiometer is used as a variable speed Name Range Default Definition
input, the total speed range will be 0 to 2.5V, which is equivalent to 0 to
Changes the rate at which the PID
512 counts displayed. When a 0 to 5V input is used, the full range of 0 to Update Rate 4 - 250 4 routine is called.(ms)
1023 counts will be displayed and the unit will operate at its best resolution.
P Scale 0 - 20 17 If a PID Scale multiplier is changed
(e.g. P Scale), the corresponding
I Scale 0 - 20 17 parameter (e.g. P) will be affected in
ENGINE RESPONSE PARAMETERS
D Scale 0 - 20 12 two ways. See below.
Name Range Default Definition
0 -100, Proportional (P) set point of the PID
P 20
100 = Max Gain control
0 -100,
I 100 = Longest 36 Integral (I) set point of the PID control
Time

D 0 -100 21 Derivative (D) set point of the PID control PID Multipliers

Adds a high-frequency, low amplitude sig-

0 - 100%.
Dither 0 nal to the actuator to prevent the butterfly
0 = No Dither
valve from sticking in harsh environment

Fuel Limit 0 - 100% 99

Maximum allowable throttle % the system If the multiplier is decreased by 1, the corresponding parameter
can command NOTE
will double. If the multiplier is increased by 1, the corresponding
parameter will halve.
If Multiple PID (See SPECIAL FUNCTIONS below) is enabled, you
NOTE
can not change the PID scale. Simply disable and re-enable.

SPECIAL FUNCTIONS
Name Range Default Definition
Enables or disables the multi-PID
tables which displays a variable map
Multiple PID Off, On OFF
over full engine speed and actuator
duty cycle range.

When multiple PID is en-

NOTE
abled, the user has the
ability to set the gain, stability, and
Deadtime at each RPM and command-
ed actuator duty cycle in a 56-position
(8 speeds by 7 positions with custom-
izable axis values) table using the “Sys-
tem Tuning” menu. The “System Tuning”
menu can be accessed through the “Op-
tions” drop-down
IGA225 Integrated Governor Actuator 7.15 PIB 2250 A
6 © 2015 Copyright All Rights Reserved
 SPECIAL FUNCTIONS (CONTINUED)
Name Range Default Definition
Overspeed Normally Enables active high output for over-
Off, On On
Open speed indication
Selects type of input for variable
Variable Speed Voltage Off, On Off speed signal. Checked = 0-5 VDC,
Unchecked = 5K Ohm Potentiometer

When a 5kΩ potentiometer is hooked up, you will have a

IMPORTANT
range of 0 - 2.5V which is 0 - 512 ADC. With 0 - 5V input
enabled, you can use the full range of 0 - 1023 ADC.

AUX
Name Range Default Definition
Aux Input Enable Off, On Off Enables or disables load sync input.

Take caution when adjusting the up/down arrows on the Engine

CAUTION
Response Parameters on the Main Menu when multiple PID is
enabled since any changes made will be reflected for the specific cell (speed vs.
position) on the table and not the entire table itself.

12 SYSTEM TROUBLESHOOTING

SYSTEM INOPERATIVE INSTABILITY

If the engine governing system does not function, the fault may be determined by perform- PROBABLE CAUSE OF
ing the voltage tests described in Steps 1 through 3. Positive (+) and negative (-) refer to INSTABILITY SYMPTOM
ABNORMAL READING
meter polarity. Should normal values be indicated during troubleshooting steps, then the
fault may be with the actuator or the wiring to the actuator. Tests are performed with battery 1. Decrease the update rate of
power on and the engine off, except where noted. See actuator publication for testing pro- the controller by decreasing the
cedure on the actuator. UPDATE Advanced param-
NORMAL PROBABLE CAUSE OF eter. (Each time UPDATE is
STEP WIRES 2. changed, P, I, and D must be
READING ABNORMAL READING An irregularity of re-adjusted.
Slow Periodic speed below 3Hz.
1. DC battery power not con- (Sometimes severe) 3. Check fuel system linkage
Battery Supply nected. during engine operation for:
Power 2. Check for blown fuse a. binding
1 Voltage
10(-) & 11(+) b. high friction
(12 or 24V DC) 3. Low battery voltage
c. poor linkage
4. Wiring error
Add a small amount of droop.
1. Gap between speed sensor
1. Increasing the P parameter
and gear teeth too great
should reduce the instability but
2. Check Gap not totally correct it.
3. Improper or defective wiring to If this is the case, there is most
Pick-Up 1.0 VAC RMS min the speed sensor likely a problem with the engine
2
3 & Ground while cranking 4. Resistance between 3 and Erratic Engine itself.
Non-Periodic
Ground should be 30 to 1200 Behavior Check for:
ohms. See specific mag pickup a. engine mis-firings
data for resistance. Defective b. an erratic fuel system
speed sensor. c. load changes on the
generator set voltage
1. SPEED parameter set too low regulator.
Actuator & 2. Short/open in actuator wiring
1.0 - 2.0 VDC
3 Battery 3. Defective speed control If unsuccessful in solving instability, contact GAC for assistance.
while cranking
1(-) & 11(+) 4. Defective actuator, see GAC@governors-america.com or call: 1-413-233-1888
Actuator Troubleshooting

720 Silver Street,

Agawam, MA 01001 USA
GAC@governors-america.com
www.governors-america.com
IGA225 Integrated Governor Actuator 7.15 PIB 2250 A
7 © 2015 Copyright All Rights Reserved

SYMPTOM
Engine Overspeeds
Overspeed shuts down engine
after running speed is reached
Overspeed shuts down engine
before running speed is reached
Actuator does not energize fully
Engine remains below desired
governed speed
720 Silver Street,
Agawam, MA 01001 USA
GAC@governors-america.com
www.governors-america.com
SYSTEM INOPERATIVE
NORMAL PROBABLE CAUSE OF
READING ABNORMAL READING
1. Do Not Crank. Apply DC power to the governor system. 1. After the actuator goes to full fuel, disconnect the speed sensor at Ter-
minal 3. If the actuator is still at full fuel-speed then the control unit is
defective.
2. If the actuator is at minimum fuel position and there exists an erroneous
position signal, then check speed sensor
2. Manually hold the engine at the desired running speed. Measure 1. If the voltage reading is 1.0 to 2.0 VDC:
the DC voltage between Terminals 1(-) & 11(+) on the speed con- a. SPEED parameter set above desired speed
trol unit. b. Defective speed control unit
2. If voltage reading is > 2.0 VDC then check for:
a. actuator binding
b. linkage binding
3. If the voltage reading is below 1.0 VDC:
a. Defective speed control unit
3. Check #TEETH parameter. 1. Incorrect number of teeth entered.
1. Examine the SPEED and OVERSPEED operating parameters for 1. SPEED parameter set too high.
the engine 2. OVERSPEED set too close to SPEED.
3. Actuator or linkage binding.
4. Speed Control unit defective.
1. Check resistance between Terminals 3 & Ground. Should be 30 1. OVERSPEED set too low
to 1200 ohms. See specific Magnetic Pick-up data for resistance. 2. If the speed sensor signal is erroneous, then check the wiring.
1. Measure the voltage at the battery while cranking. 1. If the voltage is less than:
a. 7V for a 12V system, or
b. 14V for a 24V system,
Then: Check or replace battery.
2. Momentarily connect Terminals 1 and 11. The actuator should 1. Actuator or battery wiring in error
move to the full fuel position. 2. Actuator or linkage binding
3. Defective actuator
4. Fuse opens. Check for short in actuator or harness.
1. Measure the actuator output, Terminals 1 & 2, while running un- 1. If voltage measurement is within 2 VDC of the battery supply voltage lev-
der governor control. el, then fuel control is restricted from reaching full fuel position, possibly
due to mechanical governor, carburetor spring, or linkage interference.
2. SPEED parameter set too low
IGA225 Integrated Governor Actuator 7.15 PIB 2250 A
8 © 2015 Copyright All Rights Reserved