MANUAL FOR

ROTARY

ACTUATORS Product Manual Version #1.00

ABSTRACT This manual is intended as an information guide for operating SEDEMAC's Rotary Actuator.

Doc #SED-MAN-Rotary Actuators-002 Date: 11-Sep-2017

Copyright

All rights reserved. No part of this publication may be reproduced, distributed or transmitted

by any means (including photocopying or storing in any medium by electronic means or other)

without the prior written permission of the copyright holder. Any reference to trademarked

product names used within this publication is owned by their respective companies.

SEDEMAC Mechatronics Pvt. Ltd. reserves the right to change the contents of this document

without prior notice. For permission requests and applications to reproduce any part of this

publication should be addressed to SEDEMAC Mechatronics Pvt. Ltd at below mentioned

contact details.

SEDEMAC Mechatronics Pvt. Ltd. C9-10, C Block, MIDC Bhosari Pune 411026, INDIA Web Support: Email: support@sedemac.com Website: www.sedemac.com Telephonic Support: +91-20-67313500 +91-8551039888 +91-8551041888 +91-8551043888

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Safety Instructions

General Instructions ✓ This document includes important instructions that should be followed during installation and mainte-

nance of the Generator Set controller.

✓ For safety reasons, the manufacturer recommends that this equipment be installed and serviced by

an Authorized Service personnel. Follow all applicable state and local electrical codes.

✓ Efficient and safe operation of the controller can be acquired only if the equipment is correctly oper-

ated and maintained. Many accidents arise due to ignorance or illiteracy towards the elemental rules

of safety and precautions.

The following safety notations found throughout this document indicate potentially hazardous conditions to the

operator, service personnel or the equipment.

• Highlights an essential element of a procedure to ensure correctness

• Indicates a procedure or practice, which, if not strictly observed, could result in damage or destruction of equipment

• Indicates a procedure or practice, which could result in injuring personnel or loss of life, if not followed correctly

Electrical safety ✓ Electric shock can cause severe personal injury or death.

✓ Ensure the generator set must be grounded before performing any installation or service.

✓ Generators produce high electrical voltages direct contact with it can cause fatal electrical shock. Pre-

vent contact with terminals, bare wires, connections, etc., while the generator and related equipment

are running. Do not tamper with interlocks.

✓ To handle the maximum electrical current, sizes of wire gauge used for electrical connections and wir-

ings must be appropriate to which they will be subjected to.

In operation safety ✓ Before installing Genset controller, ensure that all power voltage supplies are positively turned off at

their source. Disconnect the generator’s battery cables and remove panel fuse to prevent accidental

start up. Disconnect the cable from the battery post, indicated by a NEGATIVE, NEG, or (–) first. Re-

connect the negative cable last. Failure to do so will result in hazardous and possibly fatal electrical

shock.

✓ Remove electric power supply before removing controller or touching other electrical parts.

✓ Use extreme caution when working on electrical components. High voltage can cause injury or death.

✓ Use rubber insulative mats placed on dry wood platforms over floors that are metal or concrete when

working near Generator set or other electrical equipment.

✓ Do not wear damp clothing (Particularly wet shoes) or allow skin surface to be damp when handling

electrical equipment.

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✓ Do not operate any electrical device or wires while standing in water, while barefoot, or while hands or

feet are wet. IT MAY RESULT IN SEVERE ELECTRICAL SHOCK.

✓ Do not wear jewellery. Jewellery can cause a short circuit within electrical contacts and cause shock

or burning.

✓ In case of an accident caused by electric shock, immediately shut down the electrical power source. If

this is not possible, try to release the victim from the live conductor. AVOID DIRECT CONTACT WITH

THE VICTIM. Use a nonconducting object, like, a rope or wooden stick, to release the victim from the

live conductor. If the victim is unconscious, apply first aid and get immediate medical help.

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List of Abbreviation This list contains the list of acronyms used in this document and it can be used to refer their respective description. This List Does not contain units of measure.

Acronym Description

AC Alternating Current

ACK Acknowledge

ALT Alternator

AMF Auto Mains Failure

AUX Auxiliary

BTS Base Transceiver Station

CHG Charging

CKT Circuit

CT Ratio Current Transformer Ratio

DC Direct Current

DG Diesel Generator

DIG IN Digital Input

ENG TEMP Engine Temperature

GCU Genset Control Unit

Genset Generator Set

GND Ground

HMI Human Machine Interface

HSD High Side Driver

HWT High Water Temperature

LCD Liquid Crystal Display

LED Light Emitting Diode

LLOP Low Lube Oil Pressure

LOP Lube Oil Pressure

LVL Level

MCP Manual Control Panel

MPU Magnetic Pickup Unit

OV Over Voltage

PID Proportional Integral Derivative

PWM Pulse Width Modulation

RMS Root Mean Square

RPM Revolutions Per Minute

R-Y-B Red-Yellow-Blue

SCP Sensor Common Point

SMD State Machine Diagram

TEMP Temperature

USB Universal Serial Bus

UV Under Voltage

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Table of Contents 1 Introduction .......................................................................................................................... 7

1.1 Key Highlights of the Product .......................................................................................... 7

1.2 Product Variants .............................................................................................................. 7

2 Specifications ...................................................................................................................... 8

3 Operation .............................................................................................................................. 8

4 Installation ............................................................................................................................ 9

4.1 Dimensions ..................................................................................................................... 9

4.2 Mounting on Genset ...................................................................................................... 11

4.3 Pin Description .............................................................................................................. 12

4.4 Connection Details ........................................................................................................ 13

5 Troubleshooting ................................................................................................................. 13

6 Maintenance ....................................................................................................................... 13

Notes ......................................................................................................................................... 14

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List of Figures

Figure 1: Rotary actuators ............................................................................................................ 7

Figure 2: Small size actuator ........................................................................................................ 9

Figure 3: Medium size actuator .................................................................................................. 10

Figure 4: Large size actuator ...................................................................................................... 11

Figure 5: Actuator assembly on genset ...................................................................................... 12

Figure 6: Actuator connector pin out when viewed from the terminal insertion side ................... 12

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List of Tables Table 1: Environmental specifications .......................................................................................... 8

Table 2: Technical specifications .................................................................................................. 8

Table 3: Actuator variant specifications ........................................................................................ 8

Table 4: Actuator wiring connection details ................................................................................. 13

Table 5: Troubleshooting ............................................................................................................ 13

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1 Introduction

This document describes details of SEDEMAC’s Rotary Actuators.

SEDEMAC B12 Rotary Actuators are designed and customized for precision motion control application on wide variety of diesel/gas/gasoline engines with mechanical fuel systems. Rotary Actuators are designed to operate along with SEDEMAC’s genset controller (GCU) or B12 Electronic Control Unit (ECU) to perform electronic speed governing duty. It acts as air/fuel charge control to deliver the tight speed governing performance.

Its robust architecture supported by a heavy-duty plastic enclosure offers high rigidity and strength to sustain against harsh environmental conditions and mechanical vibrations for engine mounted application.

1.1 Key Highlights of the Product

• Tough construction for engine mounted application

• Precision motion combined high torque density

• Control capability for both rotary and inline mechanical diesel injection pumps

• Supports both fuel stop lever control as well as throttle lever control for mechanical diesel injec-tion pumps

• Low power consumption

1.2 Product Variants

• ACTZ02A (Standard Torque) – SM0000015

• ACTZ01A (Standard Torque with return spring) – SM0000014

• ACTZ06A (Medium Torque) – SM0003648

• ACTZ09A (Medium Torque with return spring) – SM0000020

• ACTZ11A (High Torque) – SM0001956

• ACTZ10A (High Torque with return spring) – SM0000021

Figure 1: Rotary actuators

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2 Specifications

SEDEMAC’s Rotary Actuators are to be powered only by SEDEMAC’s GCU or ECU. All SEDEMAC’s GCUs and ECUs are 12V and 24V complaint.

Table 1: Environmental specifications

Operating/Storage Temperature

-20 to 105˚C as per IEC 60068-2-1, 2

Vibration

5G in X, Y and Z axes for 8 – 500 Hz as per IEC 60068-2-6

Humidity

0 to 95% RH as per IEC 60068-2-78

Ingress Protection

IP56 as per IEC 60529

Table 2: Technical specifications

Power Consumption

~1A @12 or 24V

Motion

150 deg travel

Electrical Interface

4 – wire connector

Construction

Encased in tough plastic casing made of Nylon – 6 with 30% glass filled

Mounting Foot Print Dimension (For All Variants)

78 mm x 40 mm 4 Number of holes - 6.7 mm Diameter each

Table 3: Actuator variant specifications

Types Standard Torque Medium Torque High Torque

Output Torque 0.35 Nm 0.56 Nm 0.93 Nm

Weight (With Return Spring)

870 g 1270 g 1600 g

Dimensions 94 mm x 84 mm x 85 mm

94 mm x 84 mm x 121 mm

94 mm x 84 mm x 140 mm

3 Operation

When connected to a proportional Rotary Actuator and supplied with a magnetic speed sensor signal, GCU or ECU controls the wide variety of engines. Rotary Actuators provides accurate and efficient speed control for governing.

GCU or ECU reads the engine RPM through speed sensor and commands the Actuator to maintain the target governing RPM. Actuators operates the fuel stop/throttle lever via a linkage and controls the air/fuel charge.

The actuator can vary on size based on the torque output it can provide. Some Actuators are designed with return spring mounted on them. This spring pulls back the fuel stop lever to stop upon loss of

power as a safety feature.

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4 Installation

4.1 Dimensions

SEDEMAC uses three types of Rotary Actuators, small, medium and large depending on the different applications. Dimensions for these three types of actuators are given below.

Figure 2: Small size actuator

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Figure 3: Medium size actuator

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Figure 4: Large size actuator

4.2 Mounting on Genset

This section gives the generic stepwise recommendation for installation of the SEDEMAC’s Rotary Ac-tuator on the genset.

The required parts are as follows:

• Actuator

• Actuator mounting bracket

• Linkage* *Linkage transfers Actuator torque to operate the fuel stop/throttle lever to control engine RPM. The following is the stepwise procedure for assembling Rotary Actuator on genset. (Refer figure)

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• Assemble the Actuator-mounting bracket on the engine with help of fasteners.

• Fix the Actuator on the bracket with help of fasteners and bolts (M6 Bolts), size of which de-pends on the Actuator thickness. Place the wire connector cover of the Actuator on the left side, when looking from the Actuator’s shaft side.

Figure 5: Actuator assembly on genset

4.3 Pin Description

Following figure provides the pin details of 4 – wire Actuator connector.

Figure 6: Actuator connector pin out when viewed from the terminal insertion side

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4.4 Connection Details

Following table provides the connection details while connecting Actuator with GCU or ECU.

Table 4: Actuator wiring connection details

Actuator Connector B12 ECU Pin No. GCU Terminal No.

Pin No. Description

1 ACT 1 (Orange coloured wire) 5 17

4 ACT 4 (Blue coloured wire) 6 18

2 ACT 2 (Red coloured wire) 11 19

3 ACT 3 (Yellow coloured wire) 12 20

5 Troubleshooting

This section explains the common faults and their remedial actions.

Table 5: Troubleshooting

Sr. No. Faults Remedial Actions

1 Engine does not start after crank command

• Check the Linkage for loose connections

• Check if actuator powered properly by GCU or ECU

• Check the Actuator for loose connections

2 Engine cranks, but does not performing governing

• Check if Actuator wires connected correctly

For further details, please refer to Manual for B12 Electronic Governor. This manual is available on SEDEMAC’s website: www.sedemac.com

6 Maintenance

For the smooth functioning of Actuator, following maintenance is required after 3 month’s operations.

• Tightening all fasteners and bolts

• Greasing to spring, for the Actuators with spring

Follow the recommended connection details for connecting Actuator with ECU or GCU.

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Notes

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Disclaimer: Due to continuous development, the details provided in this document are subject to change without any prior notice.

SEDEMAC Mechatronics Pvt Ltd Technical Centre

C9-10, C Block, MIDC Bhosari Pune 411026, India

Manufacturing Plant

G-1, MIDC, Phase-III Chakan Industrial Area, Nighoje

Pune 410501, India

Manufacturing Plant Survey No. 64/5, Off Sinhagad Road

Vadgaon Budruk, Narhe Pune 411041, India