ESD5500E Speed Control:
Precision When You Need It

Product of the Month

GAC’s ESD5500E speed control offers versatile solutions for countless engine/actuator applications. Available in Standard, Light Force, Light Force with Enhanced Droop Control or Anti-Windup circuit for optimal control of gaseous fueled engines, the ESD5500E is a powerhouse.  

The standard model includes:

• Isochronous, variable speed, droop, idle control
• Multi-V DC
• Adjustable start fuel and speed ramping
• Switchable droop control
• Adjustable PID
• Starting fuel and speed ramping adjustment
• Auxiliary accessory input and +10 v dc supply
• Lead circuit/soft coupling
• Marine certified

Additional models include:

• ESD5520E: Multi-V DC / Light-Force (Low-Current Optimized PID) / Enhanced Droop Control
• ESD5522E: Multi-V DC / Light-Force / Enhanced Droop for Cummins EFC Forward Acting (Normally Closed)
• ESD5526E: Multi-V DC / Light-Force (Low-Current Optimized PID) / Anti-Windup Circuit (Gaseous) / Recommended for T1/T2 ATBs
• ESD5528E: Multi-V DC / Anti-Windup Circuit (Gaseous) / Recommended for T4 ATBs

We have a long history of providing solutions with the ESD5500E, from marine on tugboats to pleasure craft for engine, water jet and generator control, and on land for mobile equipment, construction and power generation. We have proven results on many engines including Baudouin, VOLVO, Deutz, MTU, Detroit, Mitsubishi and Yanmar for fine motor control.

Fun in the Field: Precise Control for Emergency Cooling Water System in Brazil

Application of the Month

A steel mill in Brazil’s Minas Gerias State contracted Distribuidora Cummins Minas Ltda (DCML), the largest Cummins distributor in Brazil, to install and maintain their emergency cooling water system.

DCML installed a KTA50-G9 engine with a PT fuel system and EFC actuator, controlled by an ESD5500E series speed control, to drive a water pump to displace 3600m3 of water (over 951,000 gallons) per hour. The pump runs on an automated system and activates when a power failure or other interruption occurs. 

The ESD5500E is programmed to restart in idle speed for 20 seconds, then accelerate under speed ramp control to 1800 RPM. The rate of acceleration is set to correspond with the opening rate of the water repression valve. The system is set to run for one hour each day to confirm function and ensure its availability in the event of an emergency.

The ESD5500E controller was selected for its ruggedness, reliability and ease of operation.

Meet Us at an Upcoming Tradeshow

• Sept. 12–14: Husker Harvest – Grand Isle, NE
• Sept. 26–28: Utility Expo – Louisville, KY
• Oct. 1–3: EGSA Fall Conference – San Antonio, TX
• Oct. 9–11: AUSA – Washington, DC
• Oct. 18–20: Equip Expo – Louisville, KY

Contact Terry Tackett to schedule a time to connect.

Celebrating Labor Day

We will be closed for Labor Day on Monday, September 4, and reopen on Tuesday, September 5.

Celebrating Summer

Did you see us on LinkedIn enjoying our MooLicious Farm delicious afternoon treat? It was the first really nice New England sunny day in a long time!

JDR100 Engine Data Reader: Small Size, Endless Abilities

Product of the Month

The JDR100 engine data reader provides a low-cost way to monitor engine parameters and codes. This tool is small in size, but endless in its abilities. Designed to support J1939 SAE data, the unit is not specific to one engine; it supports any engine system using J1939 codes. The simple display allows you view up to 10 different J1939 messages in real-time and view stored messages.

A simple PC application allows you to select any of the J1939 SAE codes sent to the ECU and add them to the viewing area. The settings can then be shared with multiple JDR units and installed anywhere the CAN Bus is available. Easy to see, easy to use, providing a quick view of data.

The JDR100-TSC1 model offers speed changes at the tap of the JDRs TSC1 button. The JDR100 series offers:

• SAE J1939 text translation
• Instant access to engine codes
• Wide temperature range (-40 °F to +185 °F [-40 °C to +85 °C])
• Built-in CAN bus termination resistor
• IP67 sealed case, non-fogging display
• Ability to fit in a 2” (51 mm) round standard panel opening
• Configurable messaging using a simple application

The TSC1 model also offers 3 speed controls and speed ramping.

Fun in the Field: Saving a California Yacht

Application of the Month

Our application engineers support customers daily with answers to all sorts of questions, from simple wiring issues to life-threatening ones on the sea.

While this month’s story took place in a safe mooring in California, it was no less challenging. A 105’ yacht, originally destined to be the retirement escape for a couple, seemed on its way to becoming a money pit. With many projects complete, the engine was still not running.

The yacht has two Scania DI12 engines; one was healthy, but the other had gone into overspeed some years back and was heavily damaged. Mechanics were able to fix the physical damage, but they were unsuccessful in getting the engine running properly.

The original damage, caused by high current emanating from a starter, also burned out the governor, a Scania 1432252. The owner noticed the unit was labelled “Made exclusively for Scania by Governors America Corp.” and reached out.

We sent a new unit (GAC DSC1004), but after three weeks, many different mechanics helping and many long-distance conversations, our chief engineer, Arni, knew he needed to hear that engine.

Immediate Results

“It wasn’t in half an hour, it wasn’t in 15 minutes, it was like one minute and he got the engine purring like a kitten,” said the boat owner about Arni’s visit. “I want to thank everyone that works at Governors America Corp for helping me solve the problem on my yacht; I really appreciate your help.”

Arni was happy to provide the solution. “The owner was such a great guy, and it was just a minor thing; I could hear it right away. The hardest part was getting to the yacht due to rerouted flights and lost luggage,” he laughed.

Ever the marine engineer, Arni took the opportunity to assess the overall ship with the owner, tweaking things that did not work properly, such as thrusters and loose fuel pump wiring to a small Cummins generator. He also helped the new owner create a to-do list of tasks that had been put off too long by the previous owner.

FAQs: Your Questions, Answered!

This Month’s Most Requested Application Solution

Steve spent this month answering a lot of questions around basic troubleshooting, and said paying attention to the details mattered. The most common solution was related to mag pickups, which play a simple but vital role in speed control, providing data to the speed controller on the actual engine speed.

His first call came in from a carnival location in Illinois. The Volvo backup generator would not start. The GAC ADC225 mounted on the side of the generator led them to call GAC. With no start, the question is always, “Did it ever work?”. In this case it did at the previous location, but not now.

Starting with the basics, Steve asked them to check a number of wiring points. When they got to the mag pickup, it was not plugged in. 

“Sometimes it’s that simple, just remembering to check your connections,” Steve said.

Similar calls came in with engines that were over-speeding and undershooting. In each case the mag pickup (rarely a GAC mag pickup) had been damaged or was incorrectly connected and needed attention. 

GAC offers a simple mag pickup guide and more installation information here.

Where Can I Find Your Installation Guides?

Product Bulletins are available for download on our website. Go to the page for the product you purchased to find PDF versions of the Product Bulletin, Sales Sheet, Users Guide and SmartView software and/or the Interface Tool used with a given governor controller.

Do You Offer Training?

We offer sales and application training tailored to your needs. GAC applications engineers will walk you through the latest applications solutions or offer refreshers on tried-and-true offerings that outlast the engine application. Choose from a selection of information or ask for what you need. We are here to help!

Happenings at GAC

Celebrating Our Independence

We took a couple of days off to celebrate Independence Day with our families, but before that we celebrated with our GAC family.

As you can see, we take our grilling very seriously! We enjoyed the downtime when we could get it, as we have lots of product building on deck to keep us busy through the summer.

DDM101 Dual Driver Module: Supporting fuel and exhaust temperature balancing adjustment to both banks of an engine

Product of the Month

The DDM101 dual actuator accessory module supports fuel and exhaust temperature balancing adjustment to both banks of an engine, enabling each to receive the same amount of fuel and produce the same amount of power.

The DDM101 is typically installed with a pair of ATB T2F throttle body actuators for gaseous fueled applications, or two ACE275K or two ADD175F series actuators for diesel engine fuel control.

The DDM is controlled with a single GAC electronic speed controller (ESD) that receives input from a thermocouple sensor mounted in each exhaust, which provides information used to balance the engine.

Fun in the Field: Total Energy Systems Installs Cummins QST Upgrade

Application of the Month

When a power and gas utility company needed its 1000KW Cummins generator QST30 controller upgraded, Grant Busse and his team from Total Energy Systems of Green Bay, Wisconsin, spent an enjoyable week in the field making sure the system worked perfectly.

Busse said, “The GAC DDM101 works amazing.” It was paired with the GAC ESD5111 speed control to provide a closed-loop system (exhaust temperature feedback). “The adjustment of the DDM101 required some initial time, but it went fine and they work really well. Between 25–100% load their exhaust temps were within less than 5°F.”

Fans of the DDM101 say it is a more reliable and user-accessible solution when compared with other alternatives.

About the Product

The 30.5L – V12 Cummins QST30 engine comes from the factory with a Cummins PCC controller and a Bosch EDC actuator mounted on each injection pump.

GAC’s Dual Driver Module (DDM101) and governor control system is the best alternative given its comparative ease of installation, simple calibration procedure and cost-effective components.

Converting to the GAC system is detailed in the GAC conversion instructions and includes the following general steps:

1. Installing an ADD175F actuator on each pump using a KT197 adapter kit.
2. Installing a K-Type thermocouple in the exhaust stream of each bank.
3. Connecting the actuators, position feedback sensors, and thermocouples to the DDM101 module and ESD5111 governor controller.

The DDM101 uses the input from the two thermocouples and two position sensors to balance and maintain an equal output from both banks of the engine while being controlled by a single governor.

The GAC solution is not compatible with the Cummins PCC controller or the Bosch injection pump-mounted actuators. These systems act as standalone complete dual pump governor systems that do not require interaction with the Cummins controller.

Total Energy Systems, LLC, has been providing power solutions for over 70 years, so when it comes to generator sales and service, they offer the best source for the finest equipment on the market at competitive prices. Their customer service representatives and technicians provide prompt service and will assist you in any way possible with any size project. They pride themselves in seeing a project through from inception to installation, and throughout the life of your equipment. “Our goal is to provide a power solution to fit your needs.”

FAQs: Your Questions, Answered!

Where Can I Get Installation Information?

Product Bulletins are available for download on our website. Go to the page for the product you purchased to find PDF versions of the Product Bulletin, Sales Sheet, Users Guide and SmartView software and/or the Interface Tool used with a given governor controller.

Do You Offer Training?

We offer sales and application training tailored to your needs. GAC applications engineers will walk you through the latest applications solutions or offer refreshers on tried-and-true offerings that outlast the engine application. Choose from a selection of information or ask for what you need. We are here to help!

This Month’s Most Requested Application Solution

This month’s number one call for applications solutions was the Cummins QST30 pump replacement. But our surprising second was replacing a Barber Colman governor Detroit Diesel DYNA 8000.

This 6V-92 best replacement uses the GAC ADC225S-24 actuator, controlled with the GAC ESD5111 speed controller. The tried-and-true combination has powered many a Detroit Diesel and is also suitable for V12-71, V8-92 and V12-92 models.

Happenings at GAC

Our Leader’s Promotion

You may not realize it, but our President and CEO, Sean Collins, is also a General in the United States Air Force. He has divided his time between running this successful design and manufacturing company and military service for nearly 30 years.

In May, General Collins became a 2-Star Major General, serving as assistant to the Surgeon General for the Department of the Air Force, Space Force. Having started his career in healthcare 40 years ago, he develops policies and best practices to support this newest military branch, while also providing similar support to the Air National Guard.

Some members of the GAC team were able to attend the ceremony, while the rest of us watched back at the plant. We are so very proud of our leader, and grateful for his service to our country.

Celebrating Independence Day

GAC will be closed on Monday, July 3, and Tuesday, July 4, to allow our employees to enjoy a long weekend with family and friends while celebrating Independence Day. We will reopen on Wednesday, July 5.

Product of the Month: Air Fuel Ratio (AFR) 200 Series Controllers

Providing Fuel Management for Gaseous-Fueled, Spark-Ignited Engines

Air Fuel Ratio (AFR) 200 Series Controllers provide a comprehensive fuel management system for gaseous-fueled, spark-ignited engines ranging from 1 L to 13 L+. The AFR’s fuel control algorithm maintains a stoichiometric or lean-burn air-fuel ratio for optimized engine performance. Users can govern engine speed in either isochronous or droop modes using Governors America Corp.’s (GAC’s) proprietary Electronic Digital Governor (EDG) algorithm. The AFR offers:

• Optimal closed-loop air-fuel ratio and delivery control.
• Actuator throttle body control.
• Integrated governing.
  • 3 Fixed Speed + Droop
  • 1 Variable Speed + Droop
  • Multi-PID Across Speed / Load Range
  • Load Synchronizing (AUX) Input
  • Dither and MAX Fuel Alert
• Air-fuel system tuning tables.
• Data monitoring with an LED display and a blink code for when a computer is not available.
• CAN / serial communication.

In addition, the AFR comes equipped with an O2 setpoints stepper, an engine sensor and a connector, harness and cast aluminum case that are environmentally sealed to IP-67.

Designed for rugged environments, the AFR is highly reliable and includes protection against reverse battery voltage, transient voltages, short circuits and loss of engine speed sensor signal or battery supply.

Users can easily configure and customize the AFR using GAC’s SmartVU software, which includes diagnostic and troubleshooting functionality and is available free for download on the GAC website.

The AFR can also meet the strict emission regulations of the United States of America, Europe and the rest of the world.

Depending on the AFR version selected, users can gain added control and engine protection through the following sensor inputs:

• Second (post-catalytic) oxygen sensor
• Engine Oil Pressure (EOP) sensor
• Engine Coolant Temperature (ECT) sensor
• Exhaust Gas Temperature (EGT) sensor; Type K thermocouple

Application of the Month

AFR Supporting Cogeneration

Cogeneration, or combined heat and power (CHP), uses an engine or power station to generate electricity and heat. Cogeneration is a highly efficient form of energy conversion and can achieve a 40 percent cost savings when compared to the price of purchasing electricity from the grid and a gas boiler for heat.

This natural gas fueled cogeneration unit (left) uses a Kubota WG752 – 3-Cylinder, 0.74L engine to power the generator. It is equipped with GAC’s:

• ATB251T1N-12 Integrated Actuator / Throttle Body
• AFR210 Integrated Air/Fuel Ratio and Speed Controller
• MXSB20-STM Venturi Mixer and Stepper Fuel Control Valve Assembly

Natural gas-fueled cogeneration units are typically used in commercial, residential and industrial applications. These cogeneration units can easily be configured with a GAC ATB (integrated actuator / throttle body assembly) and controlled by a digital or analog controller with an anti-wind-up Proportional-Integral-Derivative (PID) feature to minimize RPM over-shoot and under-shoot. GAC’s anti-wind-up algorithm in the AFR controller is specifically designed for gaseous-fueled engines. 

GAC offers a variety of engine control systems, including straight single-speed governors as well as combined air-fuel ratio and speed control systems that use the feedback from an exhaust oxygen sensor to maintain the specified air-fuel ratio.

ATB251T1N1-12

AFR210

MXSB20-STM

More Tradeshows!

EASTEC 2023

Gail Currier, John Lemoine, Sean Collins and Dave Sinaguglia met with lots of great people at EASTEC 2023 to talk about GAC and our sister company, Hawkeye Innovation.

We will also be at the following shows:

• The Utility Expo in Louisville, KY, September 26–28
• Electrical Generating Systems Association (EGSA) 2023 Fall Conference in San Antonio, TX, October 1–3
• Association of the United States Army (AUSA) Annual Meeting in Washington, DC, October 9–11
• Equip Expo  in Louisville, KY, October 18–20

Need Trade Show Banner Artwork? Let Us Know!

Templates Are Available

If you need advertising materials that include the GAC logo, please contact us for assistance.

We have templates and hands to help.

Students in Manufacturing

Making an Actuator and More

Duggan Academy teamed up with the Spark Photonics Foundation to give 6^th and 12^th graders an introduction to careers in manufacturing. GAC’s Steve Barcomb, the plant’s manufacturing engineer manager, walked the students through the steps of making an actuator. He also discussed electromagnets and the importance of precise measurements while demonstrating a caliper.  

The tour then moved to the computer numerical control (CNC) machining area, where Kevin Smith showed how he programs his CNC machine very precisely because final product measurements cannot be off more than the width of two strands of hair—which is 0.002”. That got the 6^th graders’ attention! Kevin explained it takes a lot of math to do his work, but said, “If you like your work, you will never work a day in your life.”

Product of the Month: 175 Series Integrated Pump-Mounted Actuators

Offering Outstanding Reliability and Results with No Maintenance Required

175 Series Integrated Pump-Mounted Actuators are field-proven proportional actuators designed to mount directly to Bosch “P” style and other similar fuel injection pumps. Featuring sealed internal components and no sliding parts, this design offers outstanding reliability and does not require any maintenance. In addition, this versatile actuator comes in many options, and mounting kits are available to adapt to any in-line injection pump configuration.

The 175 Series offers:

• Direct connection to the fuel control rack in place of the mechanical governor.
• Compatibility with digital or analog governors.
• A manual shut-off mechanism.
• Mounting capabilities on Bosch “P” and “A” size pumps with right-hand racks.
• A fast response of <35 msec (10–90%).
• Adjustable fuel limits.

A feedback sensor and a variety of installation kits are also available.

Installation Kits for the 175 Series

GAC has been furnishing top-notch installation kits for over 30 years, and the following is just a selection of those available for the 175 Series Integrated Pump-Mounted Actuators. Don’t hesitate to call if you do not see what you need.

KT175-RS-R

For Bosch pumps with a right-hand rack, RS/RSV governor. Works with any 175 Series Actuator. Left-hand racks are also available.

KT197

Adapts any 175 Series Actuator to a Bosch EDC Governor Housing.

KT153

For Motorpal PP4M10P1N1/PP6M10P1N1 pumps. Works with any 175 Series Actuator.

KT175A-R / KT175A-R-SA

Adapts 175 Series Actuators to a Bosch “A” pump with a right-hand rack (SA variant used with internal actuator rack return spring).

Application of the Month

Upgrading a Bosch EDC Governor System

GAC offers a complete electronic governing system conversion kit for the Cummins QST30G governing system using our ADD175F actuator.

The KT197 installation adapter kit is designed for the QST30G/30.5L, V12/760 to 1500 HP/567 to 1119 kW with Bosch in-line pump with EDC governor.

Converting to the GAC system requires the installation of an ADD175F actuator on each pump using the adapter kit. Conversion also requires installing a K-Type thermocouple in the exhaust stream of each bank, and connecting the actuators, position feedback sensors and thermocouples to the DDM101 dual driver module and an ESD5111 or ESD5221 speed controller.

The DDM101 uses the input from the two thermocouples and two position sensors to balance and maintain an equal output from both banks of the engine as it’s controlled by a single governor.

Step-by-step installation instructions are available on our website.

Trade Show News

Connect with Us at an Upcoming Event!

Sean and Terry are on the move this year, visiting partners, old friends and new acquaintances to spread the word about GAC and Hawkeye Innovation.

Hawkeye, our sister business, is GAC’s contract manufacturing and government procurement arm. It specializes in flexible contract manufacturing services utilizing GACs highly skilled employees, facilities and certified AS9100/ISO9001 process and production techniques. The Hawkeye team is committed to delivering the highest-quality manufactured hardware and electrical product solutions.

For our local friends, please find us at EASTEC at the Eastern States Exposition in West Springfield, MA, from May 16–18. Let us know you are coming and we will save you a seat! We’ll have special prizes and a lot to talk about.

We will also be at the following shows:

• The Utility Expo in Louisville, KY, from September 26–28
• The Electrical Generating Systems Association’s (EGSA) 2023 Fall Conference in San Antonio, TX, from October 1–3
• The Association of the United States Army’s (AUSA) Annual Meeting in Washington, DC, from October 9–11
• The Equip Exposition in Louisville, KY, from October 18–20

Need Trade Show Banner Artwork? Let Us Know!

If you need advertising materials that include the GAC logo, please contact us for assistance.

We have templates and hands to help.

Closing Notice

Memorial Day

Our office will be closed on Monday, May 29 for Memorial Day.

April Newsletter: EEG Series Enhanced Electronic Controllers

We’re highlighting EEG Series Enhanced Electronic Controllers and shining a spotlight on Advanced Service and Parts, LLC, one of our partners.

Product of the Month: EEG Series Enhanced Electronic Controllers

Offering Variable, Droop and Isochronous Governing Capabilities

EEG Series Enhanced Electronic Controllers offer variable, droop and isochronous governing capabilities as well as enhanced electronic governing, PID, fault protection and logging and aux inputs. Products include the EEG6500 with a built-in display, and the EEG7500 Enhanced Electronic Digital Speed Controller, which provides support to operate bidirectional motors or proportional actuators with or without a position feedback signal.

These products provide a solution for every application and engine, and each is customizable to OEM needs. Governors America Corp. (GAC) speed controllers communicate with other equipment and display live engine data. Configurations can be saved, restored and tailored to each application. OEMs can also order a pre-configured unit that is ready for installation.

FEATURES	EEG6500	EEG6550	EEG7000	EEG7500
Circuit Type / User Interface	LCD Screen	LCD Screen	USB + PC	USB + PC
Speed Range (MPU Frequency)	100 Hz – 12 kHz	100 Hz – 12 kHz	100 Hz – 12 kHz	100 Hz – 12 kHz
Speed Settings	2 Fixed Speeds or Resistive Variable Speed Input	2 Fixed Speeds or Variable Speed 0–5VDC or 4–20mA Input	3 Fixed Speeds or Variable Speed 0–5VDC or 4–20mA Input	3 Fixed Speeds with Optional Droop or Variable Speed with 0–5VDC or 4–20mA Input
Actuator Current Output Rating	10A Continuous	10A Continuous	6A Continuous	10A Continuous
J1939 / CAN	Speed Output	Advanced CAN J1939 Support with Speed Output	CAN J1939 TSC1 Support – Mini-ECU Speed Output and Speed Sync	CAN J1939 TSC1 Capable ECU Speed Sync and Fuel Curve + Virtual I/Os
Analog Input Signal Types	Resistive / 0–2.5V or 4–20mA	Resistive / 0–5V / or 4–20mA	Resistive / 0–5V / 4–20mA	Resistive / 0–5V / 4–20mA / ±3V
Positioner Mode	N/A	N/A	N/A	YES
Built-in Speed Switch	N/A	YES	YES	YES
Highlights	Built-In Fault Readout, Black Smoke Reduction, Speed Ramping	Fault Protection with Overcurrent and Overspeed Sensing and Protection	Black Smoke Reduction, Speed Ramp Control, Load Sharing/Synchronizing Option, Cummins EFC Capable	4 Analog + 2 Discrete Inputs, 1 Analog + 3 Discrete Outputs Fully Configurable I/O Definition and Routing

GC1000 Dual Fuel Conversion Kit

Advantages

• Low capital cost. Quick ROI.
• Requires no changes to the engine.
• Gives the same diesel performance with reduced emissions
• Provides cost savings by replacing diesel fuel with gaseous fuels.
• Supports various gaseous fuels including PNG, LNG and wellhead gas.
• Supports all engine sizes.
• Offers easy setup and use.
• Provides improved fuel supply logistics supporting expanded fuel options.
• Provides increased runtime during extended power outages.

About Dual Fuel

A dual fuel system allows for the simultaneous combustion of two fuels. Using an existing diesel system, gaseous fuel is introduced, and the electronic governor automatically reduces the quantity of diesel fuel. The gaseous fuel then maintains the desired power level.

A dual fuel engine can operate on 100% diesel fuel or a mixture of diesel and gaseous fuel. The optimal mixture is 30% diesel and 70% natural gas, which delivers the same power, torque and transient response as a single-fuel diesel engine. GAC’s unique and simple solution controls only the gaseous side of the engine, leaving the existing governing system untouched, which saves time and money in retrofit updates.

GAC’s dual fuel conversion controls the flow of gaseous fuel and does not affect the diesel fuel system. As the load increases, a current transformer determines the required increase in power. The gaseous fuel enters the inlet air stream through a shutoff solenoid, gas pressure regulator, mixer and fuel control valve. This solution requires no modifications to the core engine or the factory fuel management system.  

GAC Partner Spotlight

Advanced Service and Parts (ASAP)

Advanced Service and Parts truly strives to live up to its acronym “ASAP”—providing parts and solutions to customers quickly and efficiently. Whether B2B or direct to the end user, ASAP supplies relays, engine controls, block heaters, voltage regulators, battery chargers, governors and everything in between!

Dennis Risser, ASAP’s general manager, said, “What sets us apart from the competition is the ability to help our customers diagnose their problems, and then recommend and supply the correct parts to solve the issue. Most parts are in stock to ship the same day from our warehouse or our vendor to get the job done on time and on budget.” Dennis knows that word-of-mouth is still the best advertising, and clients really appreciate their friendly and knowledgeable support team!

ASAP’s customers most commonly call looking for the bestsolutions for existing systems. “Using a combination of parts, such as replacing a Cummins governor system with a GAC speed controller and another actuator, we can provide a reverse-engineered solution that is easy to install, easy to set up and far less expensive than replacing the original part.”

The number of testimonials alone will tell you this is not your average parts and distribution business. For example, one gentleman from North Carolina who was having issues with his generator said, “After many hours reading the manual’s troubleshooting charts, watching numerous YouTube videos and using the ‘scientific method,’ the generator would run perfectly—for about eight minutes.” This customer called ASAP and the company’s team helped him troubleshoot the problem. ASAP also shipped him a new part and provided him with a pre-maintenance check.

For over 20 years, ASAP has provided generator parts and solutions across the United States and abroad. The team supports nearly all brands of generators, including hard-to-find parts. At GAC, we are glad ASAP counts on us for replacement governor systems. Contact the ASAP team for all your part needs!

• Advanced Service and Parts, LLC
• 1051 E. Cumberland St.
• Lebanon, PA 17042
• Email: [email protected]
• Online: PartsForTechs.com
• Phone: (717) 274-9396

Trade Show News

Sean Collins, GAC’s president and CEO, and Terry Tackett took part in the EGSA tradeshow in Las Vegas and met with old and new friends.

The Electrical Generating Systems Association’s (EGSA) 2023 Spring Conference

Collins, a board member of the Electrical Generating Systems Association (EGSA), and Tackett had the opportunity to meet with associates as well as keynote speaker Kevin O’Leary, delivered a captivating speech touching on key topics that pressured businesses from the beginning of the pandemic in early 2020 to the current day.

FAQs from You

If you have a question about your GAC product, please let us know!

No News is Good News!

We answer a lot of questions, but sometimes, we do not know the final outcome. We love answering questions, but we also like to know how our recommendations work out. Of course, we realize people are busy and when the GAC solution works, they keep moving on!  

Here are a few stories we would love to hear more about:

• We received a call from Illinois looking to replace a Cummins EFC governor on a KTTA50-G2. The actuator was NO—normally open—so we suggested an ACB120E4-GAC paired with a ESD5111 speed controller. We mailed detailed installation instructions with the order.
• Someone in north-central New York called us looking for a governor for a DD149 V16, a Detroit Diesel 149 V16 engine. For this engine, we recommended the ACB2001 paired with an ESD5330 and a mag pickup. 
• A customer called us looking to replace a WW speed controller on a CAT3306 8250-334 with an EG-3P actuator. We recommended the ESD5120 with an extra 50 Ohm resistor.  

A customer called looking for a replacement governor for a Cummins 4BTAA3.3-G14 with Bosch India pump. Our solution was an ADE175 if the rack was on the right side, or an ALN050 with a KT231 if not. We are guessing that the rack is on the right side because a few days later, they ordered the part. What does it look like now? 

Need Trade Show Banner Artwork. Let Us Know!

Become a Featured Partner

Over the next few months, we’re changing up our newsletter by featuring our people, customers and partners. We’ll share these stories here, on LinkedIn and on our website. If you would like to be featured, give us a call or contact us.

GAC Partner Spotlight

Sistemas de Energía Sociedad Anónima (S.E.S.A.)

Sistemas de Energía Sociedad Anónima (S.E.S.A.) is an international, Venezuelan-based company serving Venezuela, Latin America and the Caribbean since 1991.  

S.E.S.A. supports industrial, agriculture, health, telecommunications, oil and maritime sectors, including full engineering design and installation, synchronization, repair and decommissioning. The team includes sales, engineering, installation and repair experts. 

S.E.S.A. connected with GAC in 2006. “Buying GAC is buying for a WHOLE life,” said manager Hernan Rendon.

A customer recently called for service after their CAT 3406 with a Woodward controller and actuator failed. When it failed a second time, S.E.S.A. suggested installing GAC products. They installed an ADC225JS-24 actuator, and by using the ESD5500E controller, they set the engine throttle to about 66Hz and connected the linkage to the fuel shut-off lever. 

After finishing all the adjustments, the customer noticed that the new GAC governor system required less than one-third of the current it previously needed to run the generator at full load. Further, GAC’s standard 2-year warranty is double what the competition offered. The customer was very happy—not only with the warranty but about the money they saved, too!

• For more information contact [email protected] 
• VEN +58 (424) 641-3328
• PAN +507 6170-8328
• USA +1 (954) 283-6509
• www.esesa.com
• S.E.S.A. Products

Planning With Our Partners

GAC likes to work directly with our partners to plan for new products and improve on existing ones. This helps us better support customer needs. Last month, GAC met with one of our combined heat and power (CHP) partners, Clarke Energy, to determine what our products can do for their current and future projects.

Clarke Energy visited the GAC facility to talk about CHP and gaseous engine control solutions. This hardworking team designs and builds CHP systems that convert energy created through gaseous fueled engines into electricity and heat in a single process. This provides energy-efficient, reliable and cost-saving solutions for large buildings. Renewable and hydrogen-fueled CHP applications are making impacts today and are gaining traction throughout the world. Federal tax incentives promote these applications for clean energy installations.

GAC has supplied Co-Energy America, which recently became part of the Clarke Energy family, for over 20 years. We have provided ATB Series actuators, magnetic speed pickups, governors, throttle bodies and more for their solutions around New England.

GAC Solutions: When It Just Has to Work!

Did you know that GAC offers sales and application training?

Tailored to your needs, GAC applications engineers can walk you through the latest applications solutions and offer refreshers on tried-and-true offerings that outlast the engine application. 

Choose from a selection of information or ask about your own needs. GAC is here to help. We provide solutions.

FAQs from You

The following is a sampling of answers to questions we received this past month. If you have a question, please let us know!

I just bought one of your products and it’s not working. Why?

A customer recently called to say the ESD5500E he had just purchased and installed showed no voltage to the controller. After going over the usual culprits such as wiring, he sent the support engineer a photo. Unfortunately, after looking at the picture, we had to tell him the unit was counterfeit. Although he was upset, he understood. Once we shipped him the genuine GAC part, the engine was up and running in no time. 

An online deal that’s too good to be true strikes again. See our website for more information on how to determine if a GAC unit is counterfeit.

I am looking to install a governor on a Ford 300 gaseous solution. What do you suggest?

We recently had several calls about adding a governor to a Ford 300. GAC loves that engine, and we have a kit for that! Read all about the installation in our application note.

We need an actuator to replace a Bosch MW pump. Please help!

Even our distributors phone home on occasion. While in the field, a distributor called us to ask what the best solution would be to replace the actuator on a Bosch MW pump. GAC developed a solution for just that scenario: an ACB275H mounted actuator using kit KT166. The installation is described in our application note.

Upcoming Trade Shows

Look for our own Terry Tacket at a host of trade shows this spring! You may have talked to him already, as he walked the ARA rental show as well as PowerGen in Orlando.

Although we are always updating our schedule, we are planning to attend the following shows:

• March 12–14 EGSA Spring Conference – Vegas – SPONSOR
• March 14–15 ConExpo – Las Vegas
• May 16–18 Eastec – West Springfield, MA – see our booth
• Sept 26–28 The Utility Expo – Louisville, KY
• Oct 9–11 AUSA – DC
• Oct 18–20 Equip Expo – Louisville, KY

Check us out on LinkedIn

Subscribe to our NewsLetter

Our First “New” Newsletter!

Over the next few months, we’re changing up our newsletter by featuring our people, customers and partners. We’ll share these stories here, on LinkedIn and on our website. If you would like to be featured, give us a call or contact us.

Partner Spotlight

PSS Governor Services

PSS Governor Services prides itself on getting the job done—and done right. For over 20 years, Dave and his team have serviced governors on and off the ship, as well as providing repair services and genuine factory parts for land and sea needs.

Dave received a call from a customer who had installed a new pump and an electric governor system, including a GAC ADC100-12, in a John Deere engine—but it was not running as hoped. After reinstalling the original pump and tuning the GAC actuator, the engine ran perfectly. Dave suggested they take the old pump and the new pump to a fuel shop and verify they are built and calibrated the same. It’s often the details that matter most—and Dave is very detail oriented.

An airport ground support company called with a unit down. The GAC ESD5221 Control replacement part was in stock and ready for will call.

Who You Gonna Call?

An application support engineer’s main job is to satisfy customers. Our support engineers do this daily, providing customized solutions and helping customers and partners find the best GAC product to meet their needs. On average, our application support engineers take on 10 requests for help each day, with over 90 requests coming in every month.

GAC support calls tend to fall into three categories: finding a known solution to a particular engine, giving advice on improving a customer’s system or helping to get an engine back online quickly.

Recently Steve, our all-around engine guy, started his day with a call from a customer looking to replace a Woodward governor on a Mitsubishi engine. The next call: what controller works with a Daewoo engine? What actuator can I use on a Bosch MW pump? How about something for a Deutz? What can I use for a governor on a 2-cycle Harley engine being used as a cement grinder? How do I get overspeed under control? For Steve, the day goes on, but each question often evolves into a friendly exchange of ideas and solutions.

Meanwhile, across the hall, GAC’s chief support engineer received a call from the middle of the ocean. Somewhere in Alaska, a ship’s generators were acting up and running too fast. On a ship, the generator is more than just lights—it powers almost everything, including the freezer where their catch is stored. The ship’s chief engineer and his handler had not slept for two days and were not making any progress. They called us for help; otherwise, they would need to return to shore, with the ship’s hold half empty.

Our chief engineer worked with the ship’s engineer to identify an electrical grounding issue. By configuring GAC’s ESD5500 controller, the engine returned to proper working order. Now, they had power and could get some sleep. The solution let them finish their trip and the job they had set out to do.

Our application engineers wear many hats, but their number one job is to provide customers with solutions. Our customers are smart; they know their engines. In that rare case when they cannot solve something, they know they can trust us to help them find an answer.

FAQs from You

The following is a sampling of answers to questions we received this past month. If you have a question, please let us know!

Is a new catalog coming out soon?

YES! We are currently working on a new catalog with our marketing partner, Market Mentors.

I’m looking to replace a BC DYN1 10606 speed control; what do you suggest?

The ESD5111 will give you a simple swap-out.

I need to replace the governor on my CAT3408. Any suggestions?

Yes. The ADC225S actuator paired with the ESD5111 will be a suitable replacement

My Cummins GTA 5.9 will not go above 50 Hz under load. How do I solve this?

A customer had installed a GAC ESD5500E on a Cummins GTA 5.9 with a WW EPG 12-volt actuator. However, the customer found they could not go above 50 Hz with a load—and 60 Hz without load. After walking the customer through some measurements, the actuator was pulling 5.5 A under load. The answer was to add a jumper between terminals H and G of the speed controller. As the installation guide noted, for 12 V systems with actuator currents above 5 A, the controller may sometimes require a jumper between terminals H and G.

Around the GAC Office

We welcomed the holiday season with a company end-of-year highlight and service award ceremony. Sean Collins, GAC’s president and CEO, led the festivities. Recognizing that the company has gone through a long couple of years, between COVID-19 and logistics and supply chain issues, Sean thanked everyone for weathering the storm well.

The highlight of the event was the presentation of service awards: one for five years of service, two for 10 years, two for 15 years and three for 25 years—that’s a total of 130 years of service! For an almost 40-year-old company, it was quite impressive.

GAC is Closed for
Presidents Day
February 20th 2022

Product of the Month: Fuel and Ignition Management System (FIMS)

For Gaseous-Fueled, Spark-Ignited Engines

The Fuel and Ignition Management System (FIMS) provides a low-pressure advanced engine management solution for gaseous-fueled, spark-ignited engines and is designed to meet tough exhaust emission control standards in the United States and across the world.

GAC provides two ways to manage control. The Air/Fuel Ratio Control (AFR) and Ignition Control Module (ICM) 200 Series together provide a low-cost solution to meet emissions standards. The AFR control creates a closed-loop fuel system when combined with five simple components:
• A digital precise stepper motor fuel control valve to adjust the flow of fuel into the system or into the static venturi mixer
• An electrically controlled throttle body valve or universal actuator to control the flow of the air/fuel mixture that enters the engine intake manifold based on engine speed and load
• An oxygen sensor that provides feedback to control how lean or rich the fuel mixture is
• A Manifold Absolute Pressure (MAP) sensor to determine engine load

The Ignition Control Module (ICM) Series controller is an intelligent electronic control module that is part of GAC’s distributor-less ignition system.

The complete-system approach results in a cost-effective solution that offers the greatest potential for improvements in both engine efficiency and exhaust emissions.

Application of the Month

FIMS Generator

Using GAC’s Fuel and Ignition Management System (FIMS), two Scania DC13 072A engines power a 270 KW generator supporting three water pumps in a Brazilian town.

The GAC ATB throttle body combined with the AFR speed controller is set to run these engines lean, saving fuel for the town.

This generator runs efficiently, consumes less fuel and produces more power.

GAC Products Used in This Solution

ATB75T4N14

AFR201

MXLB75

RPR102

Out and About

Teaching the Next Generation About Manufacturing

“Can you teach me how to make that?“ asked one of the 30 students from the Duggan Academy in Springfield, Massachusetts, during a tour of GAC’s manufacturing floor this past December.

Part of a partnership between Duggan Academy and the Spark Photonics Foundation, the tour was meant to introduce the students to careers in manufacturing.

The 8th and 11th graders, who were all wearing safety glasses and doing their best to stay within the yellow ESD lines, gained a real-world look at how engine control systems, actuators and electronics are built. The students also learned how a manufacturing plant functions through stops at the quality, assembly and, automation areas as well as the machine shop.

The visit began with a welcome from the president, CEO and owner of GAC, Sean Collins.

“I am passionate about manufacturing and passionate about the next generation being a part of manufacturing,” Collins told the students. “Making things is important to our country.” He explained that GAC is a vertically integrated manufacturer which means they both design and build products. Collins told the students to remember: “The only person to get you where you want to go is you.”

During the tour, GAC’s manufacturing engineer manager asked the students, “Do you like to make money?” After receiving a loud “Yes!” the manager used their answer to explain how a manufacturing plant must make the best use of time and space, as this ultimately affects how much money the company makes.

The students asked some great questions such as, “How much does it cost to make a coil?” and, “What do you do when the part is bad?” after they heard about what quality means from the quality manager.

“It’s extremely important to get them out and let them see what it means to be in manufacturing, to get them thinking,” said Vanessa Mahoney of the Spark Photonics Foundation , which is an integrated photonics services firm based in Waltham, Massachusetts.

GAC volunteers also spoke with many enthusiastic 11^th– and 12^th-grade students at the Springfield High School of Science and Technology. According to the volunteers, the students were engaged and excited to learn about manufacturing in the Pioneer Valley.What’s New?

Career Day at Springfield High School of Science and Technology

TechTips

The GAC KT317WB-AFR

The GAC KT317WB-AFR, a ready-to-use lean burn adapter kit for FIMS500 AFR2XX Series controllers, determines how rich or lean an engine is running at any load. Performance and operational settings are adjusted and viewed in “real-time” using GAC’s SmartVU software. The adapter kit is available in 12 or 24 V DC and provides:

• An 0.8 to 1.5 λ range.
• A plug-and-play lean burn solution.
• An included wide-band Bosch LSU4.2 Sensor.
• An accurate wide-band to narrow band conversion.

Happy Holidays!

Office Closures

Our office will reopen after the holiday season on January 3, 2023.

HAPPY HOLIDAYS!

GAC is closed for the holidays
starting December 23rd.
We will reopen January 3rd 2024

Product of the Month: ESD5526E Speed Controller

Offering Isochronous, Droop and Variable Operation

The ESD5526E, part of the ESD5500E Series of GAC speed controllers, is designed to precisely control engine speed with rapid responses to transient load changes. Ruggedly built to withstand all engine environments, the ESD’s Starting Fuel and Speed Ramp features minimize engine exhaust smoke experienced before attaining engine operating speed, providing a smooth response.

Features:

• Simple Installation and Adjustability
• Adjustable Droop and Idle Circuits
• Accessory Inputs for Load Sharing
• Variable Speed Operation
• Reverse Battery Voltage Protection
• Soft Coupling and Lead Circuit Options
• Multi-V DC
• Light-Force (Low-Current Optimized PID)
• Anti-Windup Circuit (Gaseous)

The ESD speed controller is recommended for T1/T2 ATBs . It is compatible with all GAC proportional actuators except the ADB335 and ACB2001 electric actuator since this high torque actuator also requires current limiting.

Out and About

The 2022 AUSA Annual Meeting & Exposition

GAC’s Sean Collins and Terry Tackett attended the 2022 Association of the United States Army (AUSA) Annual Meeting & Exposition to learn more about planned Army modernization, including cyber security, digital warfare, acquisition supply chain, manufacturing and improvements, which are passionate topics for Sean. They also came across some very cool warfighter tools: battlefield armed drones.

Over 30,000 people attended the event, including representatives from more than 90 countries.

What’s New?

The GAC Website!

GAC has a new and improved website!

New features include:

• Simplified access to find and read about our products
• Quick search access from the front page
• Quick requests for quotes

Happy Holidays!

Upcoming Closures

We will be closed to take inventory from November 29 through December 2, and will be closed December 24 through January 2 for the holidays. We wish all of our customers and their families the happiest of holidays and best wishes for 2023!

Product of the Month: 175 Series Actuator

Integrated Pump Mounted Actuators

The 175 Series Integrated Pump Mounted Actuators are field-proven proportional actuators designed to mount directly to Bosch P style fuel injection pumps to achieve an integrated proportional servo fuel package. The design has no sliding parts, and its components are sealed, resulting in outstanding reliability with no maintenance required. The design is versatile with numerous options and mounting kits available to adapt to other fuel pumps.

• 12/24 V DC
• Fast response; less than 35 ms (10–90%)
• Mounts directly to fuel injection Bosch P style pump in place of a mechanical governor
• Optional orderable features include feedback sensors and shutoff levers
• Supports right-hand racks
• Adjustable fuel limits
• Manual shut-off mechanism
• A large variety of installation kits are available

Application of the Month

175 on a FAW Engine

This FAW Jeifang (Wuxi Diesel) CA6DF2-17D / 125 kW / 1500 rpm / 24 V DC with Shanghai Denso in-line pump with RSV Type Governor is used in a Synchronized Power Generation application.

The conversion to a GAC ADD175A-24 actuator with installation kit KT175-RS-R and ESD5500E controller was quick and easy.

• Actuator: ADD175A-24
• Governor: ESD5500E
• Installation Kit: KT175-RS-R
• Connector and Harness Assembly: CH1215
• Magnetic Speed Pickup

Tech Tip

MSP Installation

Selecting and installing an MSP may seem complicated, but with some basic information, you can do it right.  

1. If no mounting location is available, drill and tap a hole in the flywheel housing. The threaded hole should be centered over the flywheel ring teeth, and perpendicular to the center line of the crankshaft.         
2. Insert the magnetic speed pickup into the hole and turn it until the magnetic speed pickup makes contact with the face of the gear.  

3. Back out the magnetic pickup by turning it counterclockwise about 3/4 of the way. The gap between the pickup and the gear should be between 0.020–0.035 in [0.50–0.89 mm]. Digital speed controllers may require less gap (1/4 turn) to provide an optimal signal similar to the Sensor Output shown here.       
4. Twist the wire leads for their entire length from the magnetic speed sensor to the control unit. Shielding is required if external interference is present, or the leads are longer than 10 ft [3 m].

Closing Notice

Thanksgiving

Our office will be closed on Thursday, November 24^thand Friday, November 25^th for Thanksgiving. We will return your calls on Monday, November 28^th.

See GAC videos and playlists on You Tube for details!

Product of the Month: EEG7000

Enhanced Electronic Governor

The EEG7000 Enhanced Electronic Governor is designed for use with industrial engine applications for generator sets, mechanical drives, compressor pumps and off-road mobile equipment.

• Mini – ECUTSC1 Control Capable with Diagnostic Messages (DM)

• Isochronous, Variable or Customizable Droop Governor
• 3 Fixed Speeds or Variable Speed with Direct 0-5V, 5kὩ, or 4-20mA Input
• Built-in USB Port for Easy Configuration with Free Software
• Engine Hour Meter and Service Timer
• Built-in Speed Switch Output for Crank or Overspeed
• Black Smoke Reduction, Speed Ramp Control, Load Sharing / Synchronizing Option and Cummins EFC Capable
• Fully Sealed, IP67

The 7000 precisely controls engine speed and quickly responds to transient diesel and gaseous fueled engine loads. When paired with a GAC actuator, the 7000 is a significant upgrade for any mechanical governor system that needs flexibility, precision and accurate speed control. In addition, the EEG7000 is quickly programmed through a USB port using the GAConfig Tool, consolidating popular features of past programming tools into a user-friendly, compact package. The 7000 can also be controlled directly over J1939 with other aftermarket displays.

Out and About

GAC’s Sean Collins Participates in a Fireside Chat with General David H. Petraeus at EGS

“Success in life is dealing with hurdles, setbacks and mistakes,” says General David Petraeus to his moderator Sean Collins, President of GAC, at the Electrical Generating Systems Association (EGSA) fall conference in Minneapolis, Minnesota, last month.

Retired General David H. Petraeus, former Director of the CIA and current partner at KKR, a leading global investment firm, discussed the world’s energy grid and future power needs for both military and domestic use.

“Given many years in the war zones, I have a deep appreciation for those who generate power and keep generators going. Thanks for the opportunity to spend time with you and thanks, Sean Collins, for guiding our conversation so smoothly,” said Petraeus.

Petraeus shared his thoughts on the general state of the world’s power systems, discussing the strategic challenges that America is currently facing. “Success in life is dealing with hurdles, setbacks and mistakes,” said Petraeus. These hurdles, he explained, include future needs for remote power at military bases and setups as well as the necessity for having a diverse power strategy available for domestic use.

Petraeus discussed past and present power and infrastructure requirements in Iraqi neighborhoods, U.S. domestic power grid needs and the use of renewable energy for remote military, and answered many questions on the power diversity needs here at home in the United States.

The positive feedback from the attendees was consistent throughout the conference. Collins stated, “It was great to see General Petraeus again. His ability to address the complex questions on energy, power generation and other diverse subjects was just amazing.”

General Petraeus, a prominent U.S. military figure of the post-9/11 era, is described as a leading warrior intellectual. “One of the great battle captains in American history,” says Admiral Mike Mullen.

Tech Tip

Using an External Potentiometer

A single remote speed adjustment potentiometer can be added to the ESD5xxx to adjust the engine speed continuously over a specific speed range. 

Need Help?

Contact Us

Using a GAC solution and need help? Please contact GAC for more information.

Closing Notice

Columbus Day

Our office will be closed on Monday, October 10, in observance of Columbus Day. We will reopen Tuesday, October 11.

See GAC videos and playlists on You Tube for details!

Product of the Month: PCI105

The Power Switch Interface

The PCI105 Power Control Interface switching module can switch from 50 to 60 Hz generator frequency when combined with any ESD5100, ESD5200 or ESD5500 series controller. This module is popular with rental fleets serving domestic and international markets, as well as generator support services.

Build it here, send it there, use the PCI105 to switch to the local grid frequency rating.

Use the PCI105 combined with a GAC controller to:

• Test products before export or import
• Operate equipment designed for another frequency

The potentiometers in the PCI105 let you independently adjust speed and/or frequency. The PCI105 also includes:

• A 10-V output from the controller’s Terminal P to provide power
• Multi-V DC
• A 50–60 Hz Switching Module

The PCI105 also pairs perfectly with ESD5XXX Series Speed Controllers.

Power Switch Compatible Speed Controllers

When developing a solution to the 50-60 Hz switch, GAC controller are designed to make the work easier.  Using the 10-V input on any of these GAC ESD Speed Controllers you can create the solution at one frequency and ship to a location with another frequency without retuning.

GAC’s Newest Team Member

Terry Tackett

This month, we welcome the latest addition to our family, Terry Tackett, director of business development. Terry joins us after 15 years in the commercial and recreational machine markets. 

Terry is all about family—just ask him about his daughter, Olivia. So, when a former colleague told him about GAC, he was interested in joining.

“The idea of a smaller, family-owned company appealed to me, from the family culture to the long-term growth potential for my career and company,” he said.

What GAC builds is not new to Terry, as he explained, “Engine controls and communication for a machine were the centerpieces of most solutions I was involved with in my past company.”  

Terry took off running, spending his first week on the production floor and learning about the products and the GAC family. “I’m just learning which way is up!” he said. “I want to understand GAC’s products, understand GAC/Hawkeye’s true capabilities and drive new revenue for early wins and healthy future growth for the company and team.”

When asked about what he loved about business development, he said, “I like the idea of what I do making a real impact for teammates. I love what makes up sales: meeting people, creating relationships and achieving success for the betterment of all parties. My strength is building relationships, so I enjoy exploring potential relationships.”

Terry plans to start making connections once he knows who he is working to help.

“I’m not made for cubicles,” he said. “My favorite part of my job is working with people from potential customers to colleagues and all involved in our work life.”

Terry also said listening is key. “I’ve improved as a listener, a skill that’s always a work in progress! Customers will tell you their needs if you create a trusting relationship. We can then explore how GAC can develop solutions. I’ve learned this through experience, but any sales book will tell you customers buy from those they trust.”

Look for Terry to be reaching out to listen to your needs—but contact him anytime. We are aware that there are many ideas are out there, so please give Terry time to get back to you. You will be seeing him at EGSA and in an email near you!

Tech Tip

Remember to Check the Linkage

When you think the governor system is at fault, start by looking at the linkage. When using a mechanical linkage between the actuator and the fuel system, setting the linkage length and reviewing wear and tear is crucial. The most common governor-engine linkage issues are:

• Sloppy or loose, underactive control conditions
• Overactive control
• Speed variations

What to Check For

When acceptable governor control deteriorates or changes, the linkage is one of the first areas to troubleshoot. A loose or worn linkage can not only cause unacceptable governor control, but also worn connection ends. Check for the following:

• There should be no lost motion or binding in the linkage attached between the governor and the engine. 
• Binding or friction in the linkage can cause speed variation and other problems that appear to be caused by the governor. 
• Any free play in the linkage will cause the governor to travel the distance of the free play before any fuel change is made. The governor will become overactive and provide less than optimum control. An overactive governor will also cause excessive wear in the linkage and in the governor.

One of GAC’s most common testimonials is “I can set it up and it runs forever!” Recently, a 25-year-old unit stopped running. One of GAC’s support engineers diagnosed the problem and discovered the issue was with the governor connector assembly. Now, the controller that is back to work at its Hickory Hill Greenhouse location is this ADC225 running a gen-set using a propane-fueled Ford 2.3L Katolight Gen Set. Here’s to another 25 years providing excellent speed control and load response!

Need Help?

Contact Us

Using a GAC solution and need help? Please contact GAC for more information.

Closing Notice

Labor Day

Our office will be closed on Monday, September 5 in observance of Labor Day.

See GAC videos and playlists on You Tube for details!

Product of the Month: ALR Series Actuators

Engine Mounted Reverse Acting Linear Actuators

• Simple to install—mounts in place of existing shutdown solenoid, no brackets, no linkages
• Spring return to minimum fuel
• Maintenance-free and cost-effective
• Sealed actuator
• Field-proven on a broad range of customer applications
• High-performance linear bearings
• High temperature with a compact design
• Extremely fast response

The ALR Series Electronic Linear Integral Actuators mount directly to the engine’s fuel pump in place of the electronic stop solenoids. These products exhibit high-quality construction and are designed for high-temperature operation. GAC’s unique linear electromechanical technology provides proportional actuator movement, based on actuator coil current. GAC uses precision linear ball bearings instead of bushings, and a minimum number of moving parts to improve response, precision and reliability.

ALR Series Actuators are compatible with a variety of GAC analog and digital speed controllers. Two of the most popular system combinations pair an ALR actuator with the EEC328 controller or the EEG7000 digital speed controller.

Commonly Paired Speed Controllers

Compatible with all GAC light force (lower current supported) speed controllers, our popular controllers are the EEC328 (requiring no MSP) and the EEG7000, a workhorse that supports everything.

• Low Current Optimized PID
• Isochronous operation
• No magnetic speed pickup required
• Adjustable From 40 to 80 Hz
• Rugged hard potted design
• Gain and stability adjustments
• Lower system cost

• Mini ECUTSC1 Control Capable with Diagnostic Messages (DM)
• J1939 TSC1 Capability
• Isochronous, Variable or Customizable Droop
• 3 Fixed or Variable Speeds with Direct 0-5 V, 5 kὩ, or 4-20 mA Input
• USB Port for Configuration with Free GAC Software
• Engine Hour Meter and Service Timer
• Built-in Speed Switch Output for Crank or Overspeed
• Black Smoke Reduction, Speed Ramp Control, Load Sharing / Synchronizing Option and Cummins EFC Capable
• Fully Sealed, IP67

Application Notes: ALR Solutions

Mitsubishi S4L2

The GAC SDG514 smart digital controller, combined with an ALR190-M05-12 integrated linear actuator, provides complete control of a Mitsubishi S4L2 engine, which powers a series of compact diesel welders. The ALR190-M04-12 (reverse-acting, pull actuator) connects directly to the Bosch fuel pump replacing the stop solenoid for seamless integration and incredible transient response. In addition, the SDG514 supports customer-specific settings so that every engine off the line performs the same. 

Caterpillar C2.2, C1.5 and C1.7

ALR190 Series Actuator and EEG6550 speed controller provide a complete electronic governing system for a Caterpillar C2.2 engine. The EEG6550 digital controller provides speed ramping control to significantly reduce visible exhaust smoke as the engine accelerates under load. The controller has the light force option that scales the PID governor range of adjustment for these small, low current actuators, providing the best resolution for ease of tuning the governor response parameters.

Puma Ocean Racing

The Puma Ocean Racing Team installed a Perkins N844 four-cylinder engine to adjust the keel on one of their sailboats. GAC’s ALR160-S04 actuator and SDG725 Smart Digital Governor support the application, which requires a fast, compact and flexible variable speed system that can be controlled from above or below deck. The ALR160 actuator replaced the PF pump shut-off solenoid, acting directly on the fuel control rack. Sea trials found this control system exceeded all expectations, sending the customer off to the races.

Q&A Help

Not Sure What ALR To Use? Try This Handy Chart.

See GAC videos and playlists on You Tube for details!

Product of the Month

GAC ATBs for Your Gaseous Solutions

Our actuator throttle body (ATB) features a spring return butterfly valve for safety, a maintenance-free design with precision bearings and min-max travel adjusting screws—making it the perfect solution for use in the harshest environments. 
 
The ATB Series integral throttle body electric actuators are designed to control the air or air/fuel mixture to gaseous-fueled engines with a conventional fuel mixer.
 
Features:

• Cost-effective, maintenance-free, compact design
• Rapid response to transient load condition
• Sealed to 5.0 bar (Non-CSA)
• Mounts in any position; no mechanical linkage, no mounting brackets
• Flexible design for engine, manifold and fuel mixer considerations
• Idle and max adjustment screws
• Optimal for high temperature and corrosive environmental conditions

Our ATBs are available in a host of bore sizes to fit most engines, from 25 mm to 95 mm. 

Application of the Month

Custom Generators

SES Arrow has long supported the hardworking people in the oil industry with its custom generators. These custom-built, natural-gas Arrow A90s provide 25KW of power with our ATBs. This unit uses a GAC throttle body controlled with our ESD5131 speed controller.

ATB Sizing Chart

Tech Tip

ATB Best Mounting Practices

Rigidly mount the actuator between the engine’s intake manifold and the gas mixer. The preferred mounting orientation for the GAC ATB Series is with the throttle shaft parallel to the engine crankshaft, but it can be mounted in any orientation. As a result, normal vibration from the engine will not affect the operation of the actuator.

FAQ

GAC Offers Personal Training

Did you know that we offer sales and application training? Tailored to your needs, our applications engineers can walk you through the latest solutions and offer refreshers on tried-and-true solutions that outlast the engine application.  
 
Choose from a selection of training sessions or ask us to customize one for your needs. We’re here to help.

Closed for Independence Day

Our office will be closed on Monday, July 4, in observance of Independence Day. We will resume our normal hours on Tuesday, July 5. 

See GAC videos and playlists on You Tube for details!

APPLICATION OF THE MONTH

LOWERING STARTUP SMOKE—VOLVO PENTA GEN SET

This VOLVO TAD1032 engine with a Bosch P7000 Inline pump needed a way to run smoother, quieter and with virtually no startup smoke.

The ESD5500E Series speed control unit includes features that control the fuel delivered to the engine during the start-up and acceleration.

By eliminating excess fuel, less smoke is produced resulting in environmental benefits.

COMPONENT	PART NUMBER
Actuator	ACB275-24
Installation Kit	KT275 or KT276
Magnetic Pickup	MSP6728C
Speed Controller	ESD5500E

PRODUCT OF THE MONTH

ESD5XXX SERIES — THE MOST POPULAR ANALOG GOVERNOR IN THE WORLD

Our ESD5500E governor is a long-standing, versatile and very popular governor that can be applied to multiple engine/actuator applications. It features:

• Isochronous, droop and variable speed operation
• Starting fuel and speed ramping adjustment
• Auxiliary accessory input and +10V accessory supply
• Soft coupling/lead circuit
• Marine certified

The ESD5XXX series controllers are available in standard, light force and light force with enhanced droop control. These controllers are also available with an anti-wind-up circuit for optimum control of gaseous fueled engines using our integrated actuator/throttle bodies, universal or linear actuators. 

TECH TIP

CONTROLLING EXHAUST SMOKE AT ENGINE START-UP

NEED UPDATED GAC PRODUCT INFORMATION?

See GAC videos and playlists on You Tube for details!

APPLICATION OF THE MONTH

WIRING TWO POTENTIOMETERS TO CONTROL ONE ENGINE FROM TWO LOCATIONS

When a customer was looking to add additional knob control to tune their Cooper 500 kVa main engines speed from both the bridge and the engineering control room, GACs local distributor Madhura, contacted GAC for a consultation.  

GAC developed a solution based on the ESD5330 and 2 potentiometers using a specialized wiring harness and paired with a ABC335 actuator.  The wiring harness supports the potentiometers in the control room and on the bridge. The design also includes a shutoff relay for safety. The customer added switches and lights in each room to indicate who was in control.  For this engine a 10K potentiometer was used, idle was set to 600 with a top range of 2000 RPM. 

The potentiometer adjusts the variable speeds in the range of 600 to 2000 RPM.  10K pots were used with this engine, with 600 RPM as idle and 1900 RPM / 2000 RPM as rated engine speed. As confirmed above we should have single controller for using on the engine instead of multiple devises controlling between each other.  The ESD5330 and the ADB335 are BV certified.

Once wiring is complete, the engine is tuned and the potentiometers are made available at both locations, the speed range is set for each potentiometer and then the engine is re-tuned to ensure gain and stability is in line with the desired engine results.

1. Select the switch positions for the bridge potentiometer.
2. Set 1^st potentiometer to maximum position (Full clockwise)
3. Adjust the speed setting on the ESD5330 to 2000 RPM (MAX desired speed).
4. Repeat for the second potentiometer.

For more details call GAC for directly at (413) 233-1888.

ESD5330 SPEED CONTROLLER

The ESD5300 Series speed control unit is designed to precisely control engine speed and provide fast precise response to transient engine loads. This speed control is intended to be used with all GAC Actuators including the ACB2001. A complete closed loop control system is formed with the addition of a magnetic pickup signal sensing engine speed and 24 Volt DC power.

• Two-element speed switch
• Speed ramping idle to operating speed
• Starting fuel control for lower engine exhaust emissions
• Unique actuator power drive circuit
• Accessory inputs for load sharing
• Variable speed governing
• Protection against reverse battery voltage
• Protection against transient voltage

TECH TIP

REMEMBER TO CHECK THE LINKAGE

NEED HELP WITH YOUR GAC PRODUCT INFORMATION?

Do you need a refresh of your product information? Are you not sure where to start? Are you redesigning your website? Let us help!  Contact Pam at GAC and she will send you what you need or work to create what you want.

See GAC videos and playlists on You Tube for details!

• Simple LCD User Interface, No Potentiometers or PC required
• 5K Ω resistive, 0-5 V or 4-20 mA Variable Speed Input
• Selectable Isochronous or Customizable Droop Governing
• 2 Fixed Speeds (Rated/Idle) and Variable Speed
• Speed Range to 12 kHz (4000 RPM) with Frequency Display
• Fault Protection with Overcurrent Sensing
• Adjustable Starting Fuel Strategy (Black Smoke Reduction)
• Speed Ramping (Any Transient Speed Change)
• AUX Input for Synchronizing and Load Sharing
• J1939 Engine Speed Output
• Selectable Light Force Governor – EFC Compatible
• The EEG6550 offers these additional capabilities:
  • Configurable Speed Switch
  • Selectable AUX Input Polarity
  • Hour Meter and Service Reset Hour Meter

APPLICATION OF THE MONTH

This digital governor solution provides two fixed speeds, a 1000 RPM idle, and 2000 RPM “work speed setting” when drive mode is detected, or when the unit is switched to compressor mode.

IN THE NEWS

Bureau Veritas Marine Certifications

Governors America Corp. is pleased to announce the recent certification of its marine actuators and speed controllers by Bureau Veritas (BV).  BV certification ensures ship owners and operators that the material and equipment they buy conform to international safety and regulatory requirements.  This approval further confirms that GAC products comply with recognized industry quality standards and that they are in full compliance with the BV rules, which provides further confidence from our customers for our products. Take a look at this certification and our other Marine and AS9100 Certifications!

CURRENT GAC 2021-2025 MARINE CERTIFICATIONS (See also GAC Website)

TIP OF THE MONTH

Is your product GAC Authentic?

GAC takes pride in designing and manufacturing high quality products in the U.S.A.   

The downside to creating great products is that counterfeiters love to make their product look like ours, using our reputation to sell their knock-off product.  At first glance, many of these counterfeits look like a GAC product, but they certainly do not perform like one.

For more information see GAC’s guide to counterfeits or call or email us for help.  

• Email:[email protected]
• Call: +1 413 233 1888

WHO IS HAWKEYE INNOVATION?

Hawkeye Innovation, GAC’s strategic partner, offers direct access to military sourcing. Our government procurement specialists can help you fill that contract request.

For more information contact [email protected]
Tel: +1 (413) 233-1865

See GAC videos and playlists on You Tube for details!

APPLICATION OF THE MONTH

PROVIDING RELIABILITY FOR A PERKINS POWERED GEN-SET

When a 500+ bed hospital in London called for an upgrade to its standby generator, a Perkins 4016TAG V16 engine, the GAC ACB2001 actuator and ESD5330 electronic speed controller was selected for the governing system.  Powerful enough to control the engine under no-load and full-load conditions, the parallel tests demonstrated the system’s ability to reliably synchronize and parallel the gen-set to the grid.

The ESD5330 speed controller accurately controls engine speed and provides a fast precise response to transient load changes.  With a powerful actuator drive circuit, the ESD5330 is specifically designed to work with the ACB2001 actuator which delivers 12 Ft-Lbs. [16.3 N·m] of torque over 35° of shaft rotation.

1 week after fitting the GAC system, the local authority authorized a paralleling test of the genset to ensure the system ran reliably under no-load and full-load conditions. Test trials proved 100% successful, successfully providing 1.1 MW of electrical power to the grid on a twice weekly basis with no reported failures.

Product of the Month: EEG7000

EEG7000 Enhanced Electronic Digital Speed Controller

• Mini-ECUTSC1 Control Capable with Diagnostic Messages (DM)
• Isochronous, Variable, or Customizable Droop Governing
• 3 Fixed Speeds or Variable Speed with Direct 0-5 V, 5 Ky, or 4-20 mA Input
• Built-in USB Port for Easy Configuration with Free Software
• Engine Hour Meter and Service Timer
• Built-in Speed Switch Output for Crank or Overspeed
• Black Smoke Reduction, Speed Ramp Control, Load Sharing / Synchronizing Option and Cummins EFC Capable.
• Fully Sealed, IP67

The EEG7000 Enhanced Electronic Digital Speed Controller is designed to precisely control engine speed and provide a fast precise response to transient engine loads for diesel and gaseous fueled engines. When paired with a GAC actuator the EEG is a significant upgrade for any mechanical governor system that needs flexibility, precision or accurate speed control.

The EEG is designed for industrial engine applications from generator sets, mechanical drives, pumps compressors and off-road mobile equipment.

The EEG7000 is programmed using our free software, the GAConfig Tool , consolidating the most popular features into one user friendly package. It can be controlled directly over J1939 and is completely compatible with Comap, Dynagen, and Murphy, offering a solution for every application.

Tip of the Month : WHAT GAIN LOOKS LIKE

Sometimes fine tuning the system can be frustrating.  Some say they can hear when the engine is at that sweet spot. Others use technology to reach that spot.

So what does GAIN look like.

Gain provides a proportional response to the rate of RPM change. 

Higher gain offers faster proportional response, but also higher overshoot. Lower gain offers slower proportional response.

When tuning, always set Gain at no load and adjust if needed, as load is applied.

Steady instability should respond to GAIN control.

INVESTING IN QUALITY

At GAC we strive to improve our quality.  Our recently purchased coordinate measuring machine (CMM), the Aims Revolution® HB Shop Floor 8.10.6 with a PH20 probe head, brings top of the line CMM inspection in-house with extreme detail. “Our 0.5 mm tip with unlimited articulation allows for rapid, high accuracy measurements” says Amos Bliesener.  This is critical for quality assurance in all industries.

The CMM traces parts on three axes of the machine’s coordinate system where the probe measures points on the part, with each point being unique, providing precise, reliable, repeatable inspections under all shop floor conditions.  

GUEST STAR

Many of you would know the voice, but now meet the man.

Arni Atlason, Senior Applications Engineer at Governors America Corp. (GAC), took the Oath of Allegiance, becoming an American citizen in January.  Arni’s journey to America started with his journey to GAC in 2000 when he began using GAC solutions in his engine installations.  Arni, a chief engineer in the fishing industry, visited GAC for training and was impressed. “Iceland is very Americanized, but I was impressed and thought this would be an amazing place to work.”  While visiting GAC Arni met Bill Ferry, GAC’s founder and Brig. Gen. (Dr.) Sean T. Collins, now owner and president of GAC.  “I had never met a soldier.  There was something magical about it for me. I felt honored to meet him.”  

Many years later Arni decided it was time for a change. “The thought of working for GAC stuck with me all those years. When I sent out my intent to look for a new job Bill Ferry replied right away.  GAC was so welcoming. People here in the U.S. are so friendly and open.”  Eventually Arni’s wife joined him, and both applied to become citizens. His wife was summoned first for her test in November 2020. They drove 2 hours to Lawrence MA for the interview, and due to Covid, Arni waited in the car while his wife went in for her test, returning a new U.S. citizen.  It was another year before Arni was summoned. “Good things happen slowly” said Arni.  Arni felt privileged receiving his Oath of Allegiance with Federal Court Judge Mark G. Mastroianni in Springfield MA. “It was worth the wait, it felt so much more official.”

See GAC videos and playlists on You Tube for details!

Application of the Month: MAN D2842 LE201 ENGINE

ACE275HD provides optimum performance for in-line pumps.

Tip of the Month : How do I know if my speed sensor is working?

The output voltage of a magnetic pickup is affected by three factors.

Output voltage increases with increases in the surface speed of the flywheel teeth.

Voltage decreases as the air gap between the magnetic pickup and the flywheel teeth increases.  (The optimum air gap is typically 0.020” to 0.025” {0.5 to 0.65mm})

The voltage waveform is determined by the size and shape of the gear tooth in relation to the size and shape of the sensors pole piece.

If you suspect the magnetic pickup is not functioning properly measure its resistance by disconnecting the pickup leads and check the sensors with an ohmmeter: (refer to manufacturer’s specifications for acceptable values)

1. Measure between the pickup case and leads with an ohmmeter for near-infinite resistance.
2. Confirm there are no open circuits, including the wiring harness and all connectors.
3. Inspect the sensor for mechanical damage and remove any debris that might have accumulated on the pole piece. 
4. Reset the air gap to 0.020” to 0.025” (0.5 to 0.65mm) and confirm that the sensor outputs a minimum of 1.0 VAC during cranking across the inputs to the speed control.

See GAC videos and playlists on You Tube for details!

GAC Training

Did you know that GAC offers sales and application training?  Tailored to your needs, GAC application engineers can walk you through the latest application solutions as well as provide refreshers on tried-and-true offerings that outlast the engine application.  Choose from a selection of information or ask for your own needs. GAC is here to help.

Product of the Month: EEG6500 / EEG6550 Enhanced Electronic Governor

• Simplified LCD User Interface
• Selectable Isochronous or Customizable Droop Governing
• 2 Fixed Speeds (Rated/Idle) and Variable Speed
• Adjustable Starting Fuel Strategy (Black Smoke Reduction)
• Speed Ramping (Any Transient Speed Change)
• AUX Input for Synchronizing and Load Sharing
• Selectable AUX Input Polarity
• Configurable Speed Switch
• 5K Ω resistive, 0-5 V DC or 4-20 mA Variable Speed Input
• Selectable Light Force Governor – EFC Compatible
• Hour Meter
• Service Reset Hour Meter
• J1939 Engine Speed Output Variable Speed/Load Input with Service Info and Fault Condition

Application of the Month

PSP Engines, of Humble Texas, converted a number of Caterpillar 2.2 engines to electronic governing.  They selected the GAC EEG6550 Digital Governor, ALR190-P04-12 actuator and an MSP6741 magnetic speed sensor for the systems for optimum performance and ease of installation.  The ALR190 series actuator mounts directly onto the fuel injection pump in place of the electric shut-off solenoid, and directly engages the fuel control rack.  No external linkages or mounting bracketry required.

The EEG6550 digital governor was selected for having the most applicable combination of features.  These engines will be installed as water pump drives and the speed ramping control significantly reduces visible exhaust smoke as the engine accelerates under load.  The Light Force governor feature scales the PID governor’s range of adjustment for these small, low current actuators providing the best resolution for ease of tuning the governor response parameters.

The conversion included two MSP6741 speed sensors shown threaded into the bell housing.

Tip of the Month : Controlling Black Exhaust Smoke at Engine Start-up

One of the most obvious issues with standby gen-sets is the large plume of black exhaust smoke emitted during engine startup and acceleration.  Many standard electronic governors over-fuel the engine to guarantee starting; the bigger the engine the worse the problem.  If you have multiple engines on site that all start at the same time in response to a mains failure, the amount of black smoke emitted can be very severe. 

GAC offers a reliable, proven solution, that eliminates black smoke emissions from gen-sets equipped with mechanical fuel injection systems.  A variety of digital and analog governor controllers include adjustable START FUEL and SPEED RAMPING features that enable the optimum compromise between start time, acceleration and visual exhaust smoke.

The START FUEL feature sets the initial actuator position (delivered fuel quantity) at the start of cranking and is adjustable from 0 to 100 %.  The SPEED RAMPING adjustment sets the rate of acceleration and deceleration between idle and rated speed.  These parameters can be applied to both constant and variable speed applications.

GAC Speed Controllers with Adjustable START FUEL and SPEED RAMPING Features

See GAC videos and playlists on You Tube for details!

Product of the Month: ADB335 Series Actuator

The universal electric actuator is a rotary output, proportional servo.  Easy to install, built with precision bearings and no maintenance required, this electromechanical actuator is typically used for mechanical actuation of fuel system control levers for diesel and gaseous fueled engines.   An internal spring provides fail safe operation by forcing the actuator to the fuel shut off position when the actuator is de-energized. The design combines rapid transient response with a wide rotational angle for extended linear travel and proven reliability in the field.

• 24 V DC
• 3.3 lbf.ft (4.5 N m) Net Torque
• 65° Shaft Rotation
• Die-Cast Housing
• Military Style Connector
• Available Options:
  • Position Feedback Sensor
  • Mating Connectors, Straight and 90°
  • 12′ (3658 mm) Cable Harness Assemblies with Straight or 90° Connectors
  • Mounting – Vibration Dampeners

Application of the Month

BioWorks Energy LLC of Grand Blanc, MI built a custom biogas fueled co-generation unit using a 21.9L, V12 MAN E2842 engine.  Cogeneration (cogen) through combined heat and power is the simultaneous production of electricity with the recovery and utilization of heat. 

Cogeneration is a highly efficient form of energy conversion and achieves a primary energy savings of approximately 40% compared to the separate purchase of electricity from a utility company’s electrical grid and a separate gas boiler for onsite heating.

Gaseous fueled cogen units are typically used for commercial, residential, and industrial applications and can easily be configured with a GAC ATB (integrated actuator/throttle body assembly) controlled by a variety of digital or analog governors with an ‘Anti-Wind-Up’ PID feature that minimizes RPM over-shoot and/or under-shoot.  The ‘Anti-Wind-Up’ PID is specifically designed for gaseous fueled engines

BioWorks Energy LLC has specially configured their MAN engine combining GAC’s EEG7500 Enhanced Electronic Governor, operating in the positioning control mode, with an ATB552T2F14-24 integrated actuator/throttle body equipped with a position feedback sensor for the gaseous fuel control valve system.  The EEG7500 receives a 4-20 mA input signal from the PLC, controlling the ATB’s position to properly regulate the gas flow rate for all operating conditions.  Engine speed is regulated with the ESD5330 controller that features a unique power drive circuit specifically for large, higher current actuators.

Tip of the Month : How do I know if my speed sensor is working?

If you suspect the magnetic pickup is not functioning properly, measure its resistance by disconnecting the pickup leads and check the sensors with an ohmmeter. See the manufacturer’s specifications for acceptable values.

The output voltage of a magnetic pickup is affected by three factors.

• Output voltage increases with increases in the surface speed of the flywheel teeth.
• Voltage decreases as the air gap between the magnetic pickup and the flywheel teeth increases.  (The optimum air gap is typically 0.020” to 0.025” {0.5 to 0.65mm})
• The voltage waveform is determined by the size and shape of the gear tooth in relation to the size and shape of the sensors pole piece.

1. Measure between the pickup case and leads with an ohmmeter for near infinite resistance.
2. Confirm there are no open circuits, including the wiring harness and all connectors.
3. Inspect the sensor for mechanical damage and remove any debris that might have accumulated on the pole piece. 
4. Reset the air gap to 0.020” to 0.025” (0.5 to 0.65mm) and confirm that the sensor outputs a minimum of 1.0 VAC at cranking across the inputs to the speed control.

See GAC videos and playlists on You Tube for details!

Product of the Month: AFR 200 Series Controllers

The Air Fuel Ratio (AFR) 200 series controllers provide a comprehensive fuel management system for gaseous-fueled, spark-ignited engines which incorporates a wide range of gaseous fueled engines ranging from 1 L to 13 L+.  The AFR’s fuel control algorithm maintains a stoichiometric or lean-burn air-fuel ratio for optimized engine performance. Engine speed can be governed in either isochronous or droop modes using GAC’s proprietary Electronic Digital Governor (EDG) algorithm. The AFR offers:

• Optimal closed loop air-fuel ratio and delivery control
• Actuator throttle body control
• Integrated EDGe governing
  • 3 fixed speed +Droop
  • 1 Variable Speed +Droop
  • Multi-PID across Speed / Load Range
  • Load Sharing & Synchronizing (AUX) Input
  • Dither and MAX Fuel Alert
• Air Fuel System Tuning Tables
  • Fuel P/I
  • O2 Setpoints Stepper
  • Multi-PID across speed / load range

• Engine sensor and data monitoring with LED display and blink code for use when a computer is not available.
• CAN / serial communication
• Connector, harness and cast aluminum case are environmentally sealed to IP-67.
• Ruggedly designed, highly reliable and includes protection against reverse battery voltage, transient voltages, short circuits and loss of engine speed sensor signal or battery supply.
• Easy configuration and customization using GAC’s SmartVU software including diagnostic and troubleshooting functionality, available free for download on the GAC website.

The AFR system is capable of supporting the strict emission regulations of the USA and Europe as well as the rest of the world.

Depending on the AFR version selected, the following sensor inputs are supported for added control and engine protection:

• Second (post-catalytic) oxygen sensor
• Engine Oil Pressure (EOP) sensor
• Engine Coolant Temperature (ECT) sensor
• Exhaust Gas Temperature (EGT) sensor; Type K thermocouple

Application of the Month

The GAC Air Fuel Ratio (AFR) – ATB solution provides closed loop, air-fuel ratio control with an integrated venturi mixer / control valve for low pressure gaseous fueled engines, providing the control you need for any engine based generator power solution. 

GACs comprehensive fuel management system for gaseous-fueled, spark-ignited engines ranging from 1 L to 13 L+ is a total system approach, providing a cost effective solution with the greatest potential for improvement in engine efficiency and exhaust emissions.  The air-fuel mixture is constantly adjusted between lean/rich, to operate at peak efficiency and minimize emissions using the AFRs feedback / predictive algorithm and customizable PIDs settings.

The AFR controller works alongside the GAC actuator throttle body (ATB). ATBs feature a spring return butterfly valve for safety and its maintenance free design, precision bearings, and idle air adjustment screws make it the perfect solution for use in the harshest environments, ensuring a long life.

GAC ATBs are available in a host of bore sizes to fit most engines, from 25 mm to 95 mm.

The ATB Series integral throttle body electric actuators are designed to control the air or air/fuel mixture to a gas or gaseous-fueled engine working in tandem with a conventional fuel mixer.

• Cost-effective, maintenance-free, compact design
• Rapid response to transient load condition
• Sealed to 5.0 bar
• Mounts in any position; no mechanical linkage, no mounting brackets
• Flexible design for engine, manifold, and fuel mixer considerations
• Idle and max adjustment screws
• Optional high temperature and corrosive environmental conditions

Using GAC SmartVU software the system allows for customizable, easy-to-use, quick turnaround for modifications and changes.

GAC Magnetic Speed Sensors (MAG Pickup) are used to calculate crankshaft revolutions per minute (RPM) via the input flywheel teeth value within the AFR.   

A Zero Pressure Gas Regulator is attached to the fuel inlet port on the mixer / fuel control valve assembly to regulate the pressure / flow to the assembly. While an electronic gas lockout valve increases safety and performance.  Additional tools can be used to filter exhaust, detect O2 levels, monitor oil pressure and coolant temperatures to ensure safe and constant operation.

The overall low pressure design is perfect for applications using Shale gas, Digester gas, Biogas, Landfill gas, Wellhead gas, Coalbed/seam gas.

Aged to Perfection

One of GACs most common testimonials is “ I can set it up and it runs forever!” Well recently a 25 year old unit stopped running. 

After one of GAC support engineers diagnosed the problem, a loose connector rod, the controller is back to work at its Hickory Hill Greenhouse location is this ADC225 running a gen-set using a propane fueled Ford 2.3L Katolight Gen Set.

Here’s to another 25 years providing excellent speed control and load response!

Item of the Month : AFR Lean Burn Adapter

This simple to install plug an play adapter uses Bosch LSU4.2 sensor technology replaces your narrow band sensor to optimize for emmisions.

The GAC KT317WB-AFR ready-to-use Lean Burn Adapter kit for use with AFR200 Series Controllers determines how rich or lean an engine is running at any load and compensates for changes in temperature and sensor condition.

Performance and operational settings are adjusted and viewed in real time using GAC’s SmartVu software. Set the Adjustment table in SmartVu to the required Lambda at speed vs load condition and you are done.

THROTTLE BODY SOLUTIONS

The ATB Series provides fast response and proven reliability to allow for efficient and precise control. The ATB Series actuator directly drives the throttle plate with internal return springs, ensuring that the throttle plate returns to the minimum fuel position when the actuator becomes de-energized.

ATB
Designed to control the air or air/fuel mixture to a gaseous-fueled engine

BORE DIAMETER
25, 30, 35, 40, 45, 55, 65, 75, 85, 95 mm

SPECIFICATIONS

• Sealed to 5 bar
• High temperatures
• Mounts in any position
• No mechanical linkage
• Rapid response to transient load
• Pair with the GAC AFR or other GAC Controller

SES Arrow Manufacturing, build natural gas engines equipped with a GAC ATB that supports a variety of applications.  As versatile as the ATB mounted on it.

GAC offers a complete electronic governing system for the natural gas or propane fueled Ford 300 (4.9L) in line engine using a GAC throttle body with an Impco 125 carburetor- mixer.

Aegis Energy Services provides turnkey modular combined heat and power systems. Cogeneration module includes a natural gas-fueled engine with a GAC ATB and GAC speed controller, induction generator, a microprocessor control panel, protective switchgear, and heat recovery equipment.

PSS Governor Services fully equipped governor repair facility replaces mechanical governors with the GAC throttle body and GAC speed controller to eliminate external linkages and improve performance.  This common fix is a great way to extend the life of an older generator.

The Governor Shop of Edmonton, Alberta Canada upgraded a 14.64L, 6 cylinder Caterpillar G3406 engine to a GAC control system, noting its ease of installation and superior performance. 

About the ATB

The ATB Series is designed to provide an exact fit to the various manifolds and mixers available.

The actuator is mounted rigidly between the engine’s intake manifold and the gas mixer. The preferred mounting orientation for the ATB Series is with the throttle shaft parallel to the engine crank shaft. Normal vibration from the engine will not affect the operation of the actuator.

The GAC AFR provides an optimal closed loop air-fuel ratio control system with a built-in engine speed governor capable of engine sensing, data monitoring and diagnostic capability. It supports CAN/Serial communication and is easy to configure using GAC SmartVU software.

ATB Tech Tip

The ATB should be tuned to MIN and MAX throttle speeds by adjusting the throttle screws to raise or lower the engine speed to support load.

1. Determine the engine throttle speed MIN and MAX and using a Hz meter, measure your output.
2. At the ATB, noting the arrow on the side of the ATB, locate the MIN and MAX set screws.
3. Using a small Phillips head screwdriver, remove the sealing screw. This gives you access to the inner Idle set screw.
4. Using a 2.5 mm Hex wrench, at the Idle set screw, turn the wrench clockwise to increase the fixed throttle opening.
5. After adjusting the Idle set screw, insert the sealing screw and tighten to snug plus ¼ turn.

ACB2001 For Large Diesel and Natural Gas Applications

The ACB2001 actuator is a rotary output, 24V, linear torque proportional electric servo designed for mechanical actuation of fuel system control levers requiring torques in the 5 lb·ft range. The actuator is capable of 35 degrees of rotation with torques as high as 12 lb·ft. Internal springs provide fail-safe operation by forcing the actuator to the fuel shut off position when the actuator is de-energized. Both CW and CCW output shafts are available. Engine applications include large block pumps, and dual-medium and large size carburetors.

• Rapid response
• CW/CCW rotation
• Internal return springs
• Maintenance-free
• Universal design
• Easy installation

Application of the Month: The 2001 Series 

The ACB2001 is compatible with ESD5330 and ESD5340 speed controllers that have a unique power drive circuit for optimum performance.  The ESD5330 / 5340 controllers are rugged enough too mounted in a control cabinet or in an engine mounted enclosure.  Their circuit boards are conformally coated to seal out moisture and resist vibration.

The ESD5330 / 5340

ACB2001 Actuator Mounted on Natural Gas Applications

FAQ:

Controlling Black Exhaust Smoke at Engine Start-up

One of the most obvious issues with standby gen-sets is the large plume of black exhaust smoke emitted during engine start and acceleration.  Many standard electronic governors over-fuel the engine to guarantee starting, the bigger the engine the worst the problem becomes.  If you have multiple engines on site that all start at the same time in response to a mains failure, the amount of black smoke emitted can be very severe. 

GAC offers a reliable, proven solution that eliminates black smoke emissions from gen-sets equipped with mechanical fuel injection systems.  A variety of digital and analog governor controllers include adjustable “START FUEL” and “SPEED RAMPING” features that enable the optimum compromise between start time, acceleration and visual exhaust smoke.The START FUEL feature sets the initial actuator position (delivered fuel quantity) at the start of cranking and is adjustable from 0 to 100%.  The SPEED RAMPING adjustment sets the rate of acceleration and deceleration between idle and rated speed.  These parameters can be applied to both constant and variable speed applications.

The STARTING FUEL and SPEED RAMPING adjustments control the start characteristics of the engine.  Proper adjustments provide a smooth start with minimum excess fuel to significantly reduce exhaust smoke.

Starting Fuel Adjustment:
Turning the STARTING FUEL adjustment clockwise will increase the amount of fuel delivered to the engine during cranking.  With the adjustment fully counter-clockwise, the amount of fuel delivered will be very low or zero depending upon the actuator and linkage arrangement.  With the adjustment fully clockwise, the actuator will move to the 100% fuel position during cranking. 

Speed Ramping Adjustment:

Turning the SPEEP RAMPING adjustment clockwise will slow the acceleration of the engine, it could take as long as 20 seconds depending on the speed range selected.  With the adjustment fully counter-clockwise, the ramping will effectively be eliminated and acceleration will be immediate.

Idle speed must be set for proper STARTING FUEL and SPEED RAMPING function even if the idle feature is not used.

For the initial start, insure that the STARTING FUEL potentiometer is turned full clockwise (maximum fuel) and the SPEED RAMPING is turned full counter-clockwise (fastest acceleration).

For final adjustment from idle speed, turn the START FUEL counter-clockwise until the engine speed begins to drop.  Increase STARTING FUEL slightly so idle speed is returned to the desired level.

Adjust SPEED RAMPING for the least amount of exhaust smoke during acceleration to rated speed.

New Registrar for ISO9001:2015

We here at Governors America Corp. would like to take a moment to thank the essential healthcare workers on the front lines of the Covid-19 pandemic. 

Thank you, healthcare heros

The ESD5330

The ESD5300 speed control unit is rugged enough to be placed in a control cabinet or engine mounted enclosure with other dedicated control equipment. The circuit board is conformally coated to seal out moisture and resist vibration. If water, mist, or condensation can come in contact with the controller, it should be mounted vertically. This will allow any accumulated fluids to drain away from the speed control unit.

24 V DC • Standard Unit

• Two-element speed switch
• Speed ramping idle to operating speed
• Starting fuel control for lower engine exhaust emissions
• Unique actuator power drive circuit
• Accessory inputs for load sharing
• Fixed, Droop, and Variable speed governing capable
• Protection against reverse battery voltage
• Protection against transient voltage
• The ESD5340 is available with a full fuel at start feature for rapid startup in marine applications
• The ESD5330/5340 is specified for the ACB2001 and the ADB335 / ADB335F, but is compatible with all GAC actuators

Start Shopping

APPLICATION OF THE MONTH:

Resolving a speed / frequency instability issue on a Perkins 4016, 61L, V16 engine powered gen-set. Perkins 4016TAG, 61L, V16 Engine

A 500+ bed hospital in London, UK called in GAC Distributor, IPU Engine Controls Group, now a part of ComAp Control Limited (UK), to fix an unacceptable instability problem with their emergency standby generator.  IPU supplied a GAC ACB2001 actuator and ESD5330 electronic governing system powerful enough to control the engine under no-load and full-load conditions.  Paralleling tests demonstrated the system’s ability to reliably synchronize and parallel the gen-set to the grid.

The ESD5330 governor precisely controls engine speed and provides a fast, precise response to transient load changes with every advanced feature GAC offers.  It features a powerful actuator drive circuit specifically designed for the ACB2001 actuator that delivers 12 Lb-Ft [16.3 Nm] of torque over 35° of shaft rotation.

The upgraded gen-set was returned to service on August 24^th 2015.  Follow-up checks to date have verified that it’s been operating correctly in STOR mode, successfully exporting 1.1 MW of electrical power to the grid twice a week without issue. 

Closed in Honor of Memorial DayGAC will be closed Monday, May 25th, 2020 for Memorial Day. We will reopen Tuesday, May 26th. Thank you!

To Our Valued Customers and Distributors,

Governor Charlie Baker has issued an executive order requiring all non-essential businesses in Massachusetts to close their facilities to workers, customers, and the public. The order is effective from Tuesday, March 24th at 12 p.m. and ends on April 7th. A “stay-at-home” advisory has also been issued and all non-essential employees have been instructed to work from home if applicable.

Governors America Corp. remains open, due to our status as an essential business, as defined by the Department of Homeland Security and Governor Baker’s emergency order:

https://www.cisa.gov/critical-infrastructure-sectors

https://www.mass.gov/info-details/covid-19-essential-services

GAC is committed to keeping our customers operational during this difficult time.  Please reach out to us if you have any needs or concerns.

We thank you for your support and hope that everyone stays safe and healthy.

The Governors America Corp. Team

Application of the Month:

GAC Equipped Mitsubishi S12R, 49.03L, V12 Engine
This S12R engine was equipped with an ACB2001 actuator, ESD5340 full-featured controller and an MSP6728C magnetic speed sensor to precisely regulate the generator frequency used in a marine application.

This system precisely controls engine speed and provides a fast response to transient load changes.  It features a powerful actuator drive circuit specifically designed for the ACB2001 actuator that delivers 12 Ft-Lbs. [16.3 Nm] of torque over 35° of shaft rotation.

The ESD5340 Governor – Offers Superior Full Fuel Control from Rated Operating Speed to Low Idle Due to Its Unique Combination of Features Like Dual Gain Adjustment, One for Idle and One for Operating Speed, with Independently Adjustable Acceleration and Deceleration Speed Ramping Controls.  The ESD5340 Also Includes.

• A Two Element Speed Switch
• Dual Speed Ramping from Idle to Operating Speed, with Acceleration and Deceleration Adjustments
• Wide Range Speed Control Compatible
• Start Fuel Control for Lower Exhaust Emissions
• Enhanced Start Circuit for Large Bore Engines
• Isochronous, Droop or Variable Speed Governing
• Accessory Inputs for Load Sharing
• High Current Controlled Output, Designed for the ACB2001
• Dual Gain, One at Idle & One at Operating Speed
• Adjustable Chop Frequency for Added Stability

MHI – S12R: 2,992 Cubic Inch / 49.03L V12 Engine

ACB2001 Actuator Installation

Shop the ACB2001

FAQ of the Month:  Do GAC’s Speed Controls take time to power on?

The answer is it depends.  Analog governors do not take any time to “power on”, i.e. the moment battery power is supplied to the governor, the circuit will function immediately.  Digital governors on the other hand, like all processor-based controllers, require a certain amount of time to run through the processor’s startup routine and read EEPROM for its firmware before it is ready to execute any commands.  For GAC’s digital governors this “power on” time is strictly controlled within ≤500 ms in order to meet stringent requirements, such as in an emergency backup generator’s startup sequence.

Shop Speed Controls