EGS-2000 (ELECTRONIC GOVERNOR SYSTEM)

This is a control system designed to accurately maintain output shaft speed of diesel
engine to a given order. This is third generation product (EGC 900, EGC2000). This uses
dedicated process computer (STELLA GAMMA).
System controls engine output power automatically in accordance with weather
conditions. This enables engine to run at maximum without risk of engine overload in
adverse weather.
System contains a programme module which functions as a super fast high-speed
protection while maintaining fully automatic shaft speed control.
All parameters and readings in daily use can be accessed room the from panel by operator
and privileged operator may change operational parameters by entering Password.
Initial commissioning date is entered via PC or through control unit.
Functions within EGC 2000 Fig 3.1
A) Actuator loop control
B) Tacho system
C) Set point selector
D) Shaft speed control loop
E) Engine limit curves module
F) Start/stop system
G) Minimum selector
H) Failure detection mode

The actuator is situated on engine while actuator control loop is contained in Power Unit.
RPM loop is also situated in Power Unit using Tacho Pickups for sensing engine speed.
These are situated in an engine in proximity of turning wheel. Engine limits Curve
module is a soft wave module situated within GAMMA computers. Access to limit curve
characteristics and related parameters is available from control unit.
A) Actuator control loop: This consists of position control loop which in turn uses
fast speed control and current control loops to drive actuator motor. A power drive
for control of actuator current and speed is located inside Power Unit, which also
contains GAMMA computer, which in turn contain position control loop.
Actuator control loop power electronic block requires 172V AC 3ph which is
supplied by 380/440 V 3ph via transformer size of transformer depends upon size
of actuator motor (3 sizes available depending upon engine size). Actuator
comprises of motor, brake, tacho generator, position transmitter and gearbox.
Actuator motor is brushless servomotor (no maintenance required). Actuator gear
is high precision epi-cyclic gear with extremely small back lash (requires no
periodic lubrication). Actuator has built in brake as safety feature (24VDC). If
mains supply fails or is disconnected, brake will be engaged immediately
blocking actuator in present position. Actuator Blocked signed is given.

1
 Tacho generator provides power drive with information regarding speed of motor.
Position transmitter indicates details of position of actuator to computer. These
two signals allow precise control of actuator.
Power drive combines several inputs and produces necessary power for actuator
motor. Power drives also handles Index demand and limit switches which
detects extremes of mechanical travel of actuator.
B) Tacho system: This is used to measure engine speed by two pickups, which are
situated next to turning wheel. Tacho signal processing is carried out by dedicated
input processor in computer and from here RPM signal for speed control of main
engine is passed on GAMMA CPU.
Tacho selector checks both signals whether they are within valid range. If both are
in order, (but slightly different) higher one is selected. In addition real time signal
processing is used to detect malfunction of pickup signal, which is automatically
disregarded. In nearly all cases when tacho fails signal goes to zero in which case
other tacho signal will be selected. In few cases when tacho signals gives
increased output, EGS will regulated engine speed according to this signal and
engine speed will be reduced. Hence overspeeding will be reduced. Hence
overspeeding will never take place. Failed tacho will generate signal for alarm.
C) Set point selector: This receives signal from Bridge and ECR continuously
(which could be different) as well as information from attached Remote control
unit whch informs it of control location status. Selected set point is considered as
RPM set point. This is fed to slope unit whch keeps track of order and performs
various functions with EGS. If cable error as selected input is detected or if
manoeuvring system is off line while bridge control then the set point value in
effect prior occurrence of error. This will cause alarm to be given.
D) Shaft speed control: Optimal controller takes care of filtering the input signals
and calculations of Actuator index demand. Parameters within optimal controller
vary according to engine conditions, and controller provides 3 different modes of
operation.
RPM Mode: Constant RPM is maintained even in rough weather. This requires
hard work by actuator which would entail some wear on mechanical components
of engine, fuel pump, fuel racks and actuator.
Power Mode: Engine power is maintained constant. This gives optimal effect on
engine operation in moderate/rough weather conditions. Wear and tear as actuator
and fuel racks is minimized. Thermal load fluctuations are likewise reduced.
Index Mode: Will maintain fixed index. Used when measuring engine
performance. RPM control is automatically retained if RPM becomes too high.
Auto select Mode: Optimal controller will automatically select RPM/Power mode
depending upon weather change over criterion is sea state 3 (Beau fort 3)
E) Engine limits module: Filtered scavenge pressure signal is transmitted to
scavenge. Air limit block as also filter RPM signal and actuator index demand is
passed on to MIN selector.
Scavenge air limit function assures correct amount fuel injected in relation to
available scavenge air. This takes care of sudden acceleration and temporary lack

2
 of air and prevents incomplete combustion /back smoke. This will also prevent
engine thermal overloading. Values on X and Y are programmed by PC or front
panel on control unit (value are recommended by engine maker). This module
also has RPM load limitation function purpose of which is protect engine against
torque overload. (see figure)
Engine limit pre-warning (optional): For 2 above curves tow additional curves
may be chosen (parallel to limit curves) but with lower index value. When these
lower value limits are reached alarm will be given.
F) Minimum selector: Limits the actuator index demand (from optimal controller)
before passing on signal to power electronics/actuator. Actuator index demand is
limited by
(I)Scavenge air limit
(II)RPM load limit
(III) Index max (max index set from control panel)
Index will be limited to zero whenever STOOP or SHUT DOWN signal is
active.
G) Start/stop system: Controls index during start/stop of diesel engine. When
stop/shut down signal is received index is brought to zero. Value will be
maintained for length of time. If actual RPM is reached within this length of time
index will be controlled by optimal controller. When time is over actuator index
goes on line if RPM has not reached the ordered value.
During start signal pre-determined index as set. This if EGS 2000 is started up
after mains failure and engine is already tunning at RPM value above start level
RPM this function is automatically by-passed as also during Cancel limits.
At control unit higher value of start level can be selected (repeated start after
failure to start).
H) Failure detection mode: Following categories of failure detection is available
a. Cable failure of all input signals.
b. Pick up error-on tacho system.
c. System supervision-including remote control system, tacho system,
control unit, actuator power drive, and c/over system.
d. Actuator supervision including motor temperature and position error.
e. Supervision of input/output system for computer.
f. Power source supervision including DC voltge and battery supply.
g. All types of computer memory circuit as well as CPU functions.
h. Alarm released for EGS 2000 subject to test.
i. Alarm for illegal parameter setup in GAMMA computer.
j. Alarm for VIT option safety limit active.

If a cable failure occurs in any monitored connection between EGS 2000 and
environment t which is connected this will be displayed in alarm panel (unit LDC
display). Generally no change in engine operation will occur, but some special cases for
reasons of engine safety will affect engine operation.

3
EGS 2000 has a circuit to monitor the operation of computer for computer hardware
failure. If error is detected alarm is given and actuator is blocked and all programme
execution is terminated. If error is detected during Start up procedure, EGS will not
allow start actuator is blocked and alarm is given.
[Load limit cancel is available when it ;is necessary to maintain max. engine output
despite the fact Scavenge Air/RPM Load Limit is active. Use of this function is at
discretion of operator who should be aware that he could be overloading engine.

Options available in EGS 2000:

Synchronization pick up: Normally used on engines with 4 or 5 cylinders. Fuel
pump index will be synchronized with TDC of one of the cylinders each
revolution.
Critical speed module: Used to protect M.E. from barred speed range. (It shall
be noted that there shall never be critical speed modules active both in Governor
and associated Bridge Manoeuvring System).
Slope on RPM order Module: This facility is used when instantaneous jumps in
RPM are to be avoided even though speed setting command might be made as
step in handle position. It shall be noted that this module shall never be active in
Governor and Bridge Manoeuvring System.

Chapter 5
Preventive maintenance

5.1 Regular checks.

No periodical maintenance is required on EGS 2000. Components, which take the
hardest punishment the ACTUATOR and GEARBOX, are of the highest quality. The
ACTUATOR is brush-less i.e. contains no carbon brushes, which require regular checks
and replacement. The GEARBOX is sealed and contains its own lubrication, which
should last the lifetime of the vessel.
However in order to assure that all is well then the following procedure shall be carried
out two or three times a year, (the engine must be STOPPED, and START BLOCKED
during this test ):-
1) Check that connections to the SCAVENGE AIR PRESSURE
TRANSDUCER are tight, clean and show no signs of corrosion.
2) Check that the TACHO PICKUPS are located properly in their brackets
and that connections to the relevant junction box are tight, clean and show
no signs of corrosion.
3) Check that connections to the ACTUATOR are tight, clean and show no
signs of corrosion. Check that the ACTUATOR links are clean and show
no signs of overload (I.e. twisting, bending, loose bearings).
4) Check that the links between the EGS Actuator and the fuel pumps have
no sign of backlash. If a backlash in excess of 0.3 mm exists the
connection rods should be adjusted.

4
 5) Open the EGS 2000 Power Unit visually check that all cables are sited
properly. Close the power unit door.
6) Carry out the self-test procedure by pressing the [TEST] key on the
Control Unit. Check that the display is in order and that no alarm
conditions occur.

5.2 Tacho system checks

The tacho system consists of two tacho pickups, and relevant input cards in the EGS
2000 power unit. The EGS 2000 will normally give an alarm if one of these circuits fails
however the following procedure may be carried out every 6 months.
To carry out these tacho checks, the engine must be RUNNING the vessel in SEA
CONDITION and the ACCESS code for either Privileged User or LVM technician
inserted.
1) Select TACHO 1 as operational tacho. Return to the normal menu. Check that the
tacho indicator read TACHO 1 note the RPM reading.
2) Select TACHO 2 as the operational tacho. Return to the normal menu. Check that
the tacho indicator reads TACHO 2 . Note the RPM reading. This should be
the same as that for TACHO 1 (a small divergence of 0.1 RPM is acceptable).
3) Select AUTO. Return to the normal menu.

For details of MENU and ACCESS operations see sections 3.3.6 and 4.1.1 in this
manual.