MEC 12-75 VDC

Variable Speed
Generator Controller
INTRODUCTION
The Speed Load Control Mecc Alte Engine Controller (MEC) 12-75
VDC quickly and accurately adjusts engine speed, controlling the
generators electrical load by controlling generator voltage, not
actual speed. This variable speed operation results in decreased
noise, significantly reduces fuel consumption and increases engine
life.
The MEC 12-75 VDC, when connected to a proportional actuator and
supplied with voltage signal from a DC generator, uses DC voltage
to control speed instead of actual engine speed. It supports a wide
variety of small engines.
The MEC 12-75 VDC governor is easily paired with GAC ALN-, ALR-,
or 120-Series actuators and supports both 12 and 24 V DC.

SAMPLE ACTUATOR PAIRINGS AND USES

Engine applications include diesel and gaseous
ALN-Series
fueled.
Engines with an PF style pumps equipped with
ALN-Series
shut down solenoid.

ADC120S-12 Ideal for fuel systems on engines up to 150 HP.

SPECIFICATIONS PHYSICAL
POWER 1.02 x 4 x 4.67 in
Dimensions
[25.91 x 101.60 x 118.62
Battery Supply 12 and 24 V DC
Weight 12 ozf (347 gf)
Input Range 12 to 75 V DC
10 - 2000 Hz, +/-4.0 g
Vibration and Shock
Duty Cycle 0 - 100 % 20 G, 11 ms
PWM Output
Frequency 50 – 450 Hz
Mounting Vertical mounting preferred
Operating Temperature -30 to 85 °C [-22 to 185°F]
Operating Hours 10,000 hours
Maximum Current 6 A DC
Relative Humidity 38 °C @ 97-100 %
Storage Temperature -55 to 125 °C [-67 to 257°F]

WIRING AND DIMENSIONS

An overspeed shutdown device, independent of the governor system, should be provided to prevent loss of engine control which may cause
personal injury or equipment damage. A secondary shutoff device, such as a fuel solenoid, must be used.
CONNECTING THE ACTUATOR

Connect the actuator to the MEC 12-75 VDC following your specific actuator’s installation instructions.
The potentiometers on the MEC 12-75 VDC will adjust the voltage to set speed. Reverse voltage protection is built in to the design.

• Electric actuator linkage must be correctly set before adjustments are made to the Speed/Load Controller.

• Mount in a cabinet, engine enclosure, or sealed metal box.

• Vertical orientation allows for the draining of fluids in moist environments.

• U
 se shielded cable for all external connections to the controller. Use 16 AWG, 12.0 ft [3.66 m] for 12 V DC systems, 18 AWG, 12.0 ft
[3.66 m] for 24 V DC systems.

www.meccalte.com
MEC 12-75 VDC
Variable Speed Generator Controller
CONNECTING THE ACTUATOR

• One end of each shield, including the speed sensor shield, should be grounded to a single point on the controller case.

• Do not overtighten terminal connections. Torque to no greater than 9.0 in-lb ±2.5 [1.01 ±0.28 N∙m].

GENERATOR
SIGNAL

ACTUATOR (-)

ACTUATOR (+)

TERMINAL CONNECTS TO
A Generator Signal (+)
B NA
C NA
D NA
J H G F E D C B A
+ - - + - + E Generator Signal (-)
ACTUATOR 12/24 V DC GEN OUTPUT (DC VOLT)
F Battery (+)
G Battery (-)

SPEED LOAD CONTROL

H Actuator (-)
MODEL: MEC 12-75 VDC
DC SPEED CONTROLLER POWERED BY GAC MADE IN AGAWAM, MA USA
J Actuator (+)
S/N:
BOOST
STAB

GAIN

VOLT
GEN

STARTUP AND ADJUSTMENTS

Once the actuator is mounted on the engine and the controller is connected to the engine, you are ready to start the engine and continue
setup.
STARTING THE ENGINE
The controller controls generator voltage, not speed.

1. Set gain (GAIN) and stability (STAB) potentiometers to the middle settings (50 % - 6 o’clock) before starting the engine.

2. Set the running speed on the engine to no load.

3. The controller speed setting is factory set at approximately engine idle speed, 14 V DC at nominal for 12 V DC system, 28 V DC
nominal for a 24 V DC system.
4. Crank the engine with DC power applied to the governor system. The actuator will energize to the maximum voltage (28 V DC) until
the engine starts. The voltage (GEN VOLT) potentiometer is a 25-turn potentiometer, you may have to turn it clockwise several turns
before the engine starts.
5. Once the engine starts, power will peak to 28 V DC then back to 50% settings. If the engine is unstable after starting, turn the GAIN
adjustment counterclockwise until the engine stabilizes.

6. Use the BOOST potentiometer to further tune the setting 0 – 5 V DC.

The governed voltage setpoint is increased by rotating the GEN VOLT adjustment control clockwise.
NOTE
This is a 25-turn potentiometer; you may have to turn it several turns before noticing a change.

www.meccalte.com
MEC 12-75 VDC
Variable Speed Generator Controller
STARTING THE ENGINE
The Speed/Load Controller is operating correctly if the following are true:

• When applying load, engine speed promptly increases without a large initial decrease in RPM.

• When removing load, engine speed promptly decreases without an initial surge.

• Engine speed does not rapidly fluctuate up and down (hunting).

ADJUSTING FOR STABILITY

Once the engine is at operating speed and at no-load, complete the following adjustments.

STEP ADJUSTMENT

1. Rotate the GAIN potentiometer adjustment clockwise until the engine becomes unstable.
2. Gradually move this adjustment counterclockwise until stability returns.
1
3. Move GAIN an additional 10° (1/8 of a turn) further counter-clockwise to ensure stable performance (270°
potentiometer).

1. Rotate the STABILITY potentiometer (STAB) adjustment clockwise until the engine becomes unstable.
2. Gradually move this adjustment counterclockwise until stability returns.
2
3. Move STABILITY an additional 10° (1/8 of a turn) further counter-clockwise to ensure stable performance (270°
potentiometer).

1. Apply rated load.

3 • When applying rated load, the engine speed should slowly increase without a large initial change in RPM.
• When removing load, the engine speed should slowly decrease without a large change in RPM.

If instability cannot be corrected or further performance improvements are required, refer to the Troubleshooting section in
4
this guide or call your GAC representative.

TROUBLESHOOTING
The rpm required to reach any particular voltage is determined by the load: the lighter the load, the lower the rpm needed to reach the
specified voltage. The float voltage of a 24 volt battery is typically 27.6 volts.
SYSTEM INOPERATIVE
If the governing system does not function, check the following:

1. DC battery power not connected. Check for blown fuse, switch off power.

2. Low battery voltage

3. Wiring error

INSTABILITY
INSTABILITY SYMPTOM PROBABLE CAUSE

1. Readjust Gain and Stability for optimum control.

Fast Periodic Engine jitter at 3 Hz or faster
2. Turn off other electrical equipment that may be causing interference.

1. Fine tune Gain using the Boost pot.

2. Check fuel system linkage during engine operation for:
Slow Periodic Irregular speed below 3 Hz
A. binding
B. high friction
C. poor linkage

www.meccalte.com
MEC 12-75 VDC
Variable Speed Generator Controller
INSTABILITY SYMPTOM PROBABLE CAUSE

Increasing the Gain should reduce the instability but not totally correct it. If this is
the case, there is most likely a problem with the engine itself. Check for:
Non-Periodic Non-Periodic A. engine mis-firings
B. an erratic fuel system
C. load changes on the generator set voltage regulator

UNSATISFACTORY PERFORMANCE
SYMPTOM STEPS PROBABLE CAUSE

Do Not Crank. Apply DC power to the

Generated residual voltage must be 10 volts or higher for this test.
governor system.

Measure the DC voltage between actuator terminals on the speed control unit.
• I f the voltage reading is 2.0 to 3.0 V DC check for:
Engine 1. SPEED adjustment set above desired speed
overspeed 2. Possible defective speed control unit
Manually hold the engine at the desired
running speed. • If voltage reading is > 3.0 V DC check for:
1. Actuator binding
2. Linkage binding
• If voltage reading is below 1.0 V DC the speed control unit may be defective.

Increase the GAIN setting CW and also turn stability CW as much as possible
Overspeed without causing instability.
Low GAIN setting.
during start up
Check the actuator for binding or friction.

If the voltage is less than the following, check or replace battery

DC voltage at the actuator should be 0.8
to 1.5 V DC less than the actual battery • 7 V for a 12 V DC system, or
voltage, but not less than 8 V DC.
• 14 V for a 24 V DC system,
Actuator does
not energize If not:
fully
Connect actuator terminals to battery. • A
 ctuator or battery wiring in error. See your actuators troubleshooting guide
The actuator should move to the for more testing information.
full fuel position. • Actuator or linkage binding
• Defective actuator

Engine speed Measure the actuator output terminals If voltage measurement is within 2 V DC of the battery supply voltage level,
below desired while running under governor control. then fuel control may be restricted from reaching full fuel position, possibly
governed See your actuators troubleshooting due to mechanical governor, carburetor spring, or linkage interference.
speed guide for expected measurements. GEN VOLT adjustment may be set too low.

www.meccalte.com