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User Manuals Apecs 500

1. 6 Beyond basic calibration there are many parameters associated with APECS that can help enhance the performance of your engine Read the section in this chapter on Understanding APECS Calibration Parameters and decide on the parameters you would like to adjust Woodward 13 APECS 500 Electronic Engine Speed Governing System Manual SE 4107 7 Access Change APECS Calibration option from the Calibrate Menu and select the desired parameter from the appropriate category Adjust the value of the parameter as needed 8 Repeat Step 4 until all desired parameters have been adjusted and satisfactory engine performance has been achieved 9 You do not need to save the new calibration settings All settings are automatically saved in the controller and remain in memory after shutdown Saving a Calibration Set to File After satisfactory engine performance is achieved it is recommended that you save the calibration set to a file e A saved file allows you to experiment with other calibration settings and still be able to recall the saved calibration set e A saved calibration set can be used for configuring additional APECS units To Save a Calibration Set to File 1 Access the File Menu to activate the Save APECS Cal to File command 2 Enter a file name to save the calibration data to a designated file 3 When prompted to edit the comment list enter information that will help you keep track of specific engine
2. rrrrarrrnnnnrnnnnnrrvnnnennannennannrnnnnnnnnnnnnnnnnennannennnnsennnnennnnnsennn 16 Governor Gain Calibration Parameters rrrnnnrnnnnnnnnnnrvvrrnnnnnrennnnnnrnrnnrrnnnnnennnnnnsnne 17 PID Oams AUSTIN EE onto 17 PID Gain Settings Response Plots ccccccconncnncccnonncnncccnoncnnnononanononononanennnoss 17 Engine Set Speed Calibration Parameters cocoocccoooooocccnnnccnnnnnnnnnnnnnnnnnnnnanncnnnnnnnos 18 Speed Input Configuration Parameters cccccccccconncccnnncccnnnnonnnnnnnnonnnnnannnnnnononononans 19 Engine Start Calibration Parameters oooonnccnnncccconononcconnncnonononnnnnnnnnnnnnnannnnnnononos 19 Diagnostics Calibration Parameters rrrrnrrnnnrrrvnrrnnnnnrvnrnnnnnnennnnnnnnsrnnnnnnsnsennnnne 20 Overspeed Underspeed Protection oocccccccccccncccnnccnnnnccnnnnonnncnnnnnnnnnnnnos 20 Actuator Output Calibration ParamMeterS cccccccoonncnncccconnconcnononnnnnononannnnnonnnanennnoss 21 Calibration Setup amp Configuration Parameters Flowchart oocccccccconccnnccccnnnos 22 CHAPTER 4 ACT OPERATION amnnnnnnnnnnnnannnnnnnnsnnnnnnnnnnannnnnnnnsnnnnnnnnnnanennnnnnen 24 A EE EE 24 AMT 24 Set up Requirements occcccccconccnncccnonconnconnnncnnnonnnnncnnnonnnnnnnnnnnnnnncnnnonnnnncnnnnnnnns 24 LE LOM 0 EE EEE EE EEE EE EE ane 24 Software Set Up ccccccccsseecceccceseeceescceseeceeccceseeceescceseeeeeccceseeeessccsseeeessccess 25 Basic ACT Operation scabiceecnizscdecdsssceettetsccesisedacesetsS
3. APECS 500 is a programmable engine governor Changing APECS calibration parameters is the means to configure the APECS controller for specific engines applications and environments and for adjusting PID gains The calibration parameters have been organized into categories for your convenience Browse through the categories to view the specific parameter you want to change or adjust some parameters must be set before the engine can run Other parameters can be adjusted while the engine is running A complete list of parameters appears in Understanding APECS Calibration in Chapter 3 All adjustments are stored immediately in non volatile memory in the APECS unit The APECS controller will retain the changes even if power is lost or the ACT is disconnected To Change APECS Calibration Parameters 1 Choose Calibrate gt Change APECS Calibration 2 Set the View Filter to select a group of parameters 3 Use F5 F6 to scroll through the list 4 To change the highlighted parameter Enter the new value in the New Value field Press lt Enter gt Woodward 31 APECS 500 Electronic Engine Speed Governing System Manual SE 4107 The new value is written to the controller and then read back with the result placed in the APECS Value field 5 Press lt Esc gt to exit Download Cal File to APECS The Download Cal File to APECS command allows you to download the entire calibration set from a file to
4. Serial Port The application will Serial Controller Connection Demo Mode 7 display the following screen ee ard C Com ECS 2 Choose a port and click OK v gt This screen will be displayed on application startup if a controller cannot be found at the last selected port and can be changed any time after the application has started C APECS 4000 C APECS 4500 C APECS 5000 Demo Mode This mode will use a calibration file Demo 000 and use random numbers for values requested from the controller COM 1 COM 2 This mode will look for a controller attached to the selected serial port An error message will be displayed AFTER you click OK if a controller cannot be found or if the port cannot be opened COM ports outside of this range can be used by editing the default COM port registry key for this application Woodward 41 APECS 500 Electronic Engine Speed Governing System Manual SE 4107 Help Menu The Help Menu provides access to the online user s manual and other information helpful to your use of the calibration tool The following commands are available under the Help Menu e Help Topics e About ACT e User s Manual Help Topics This command allows you to search for specific information by displaying software menu items or through key words 1 Click on Contents for an outline of the software applications listed by menu items 2 Click on Index or Find to locate a specific to
5. 1 In Convert APECS Cal to Text operation the calibration set that is converted is from the APECS unit 2 In Convert Cal File to Text operation the calibration set that is converted is from a previously saved file You may use the View Text File command to view text files Convert APECS Cal to Text This command allows you to create a text file of APECS calibration data for viewing or printing from any text editor utility in Windows A printed copy of the calibration data can be useful for future reference To Convert APECS Calibration to Text 1 Choose File gt Convert APECS Cal to Text 2 ACT will prompt you to enter a name to save the text file Enter a file and click OK ACT will read all of the calibration values from the controller create and save a text file with the parameter names values and units then display the file using the default text viewer Convert Cal File to Text This command allows you to convert a previously saved ACT calibration file to a text file for viewing or printing from any text editor utility in Windows A printed copy of the calibration data can be useful for future reference To Convert Cal File to Text Choose File gt Convert Cal File to Text 2 ACT will prompt you to enter a name to save the text file Enter a file and click OK ACT will read all of the calibration values from the controller create and save a text file with the parameter names values and units then
6. standard classes We also offer customized classes which can be tailored to your needs and can be held at one of our locations or at your site This training conducted by experienced personnel will assure that you will be able to maintain system reliability and availability For information concerning training please contact us via telephone email us or use our website and reference Customer Services and then Product Training Field Service engineering on site support is available depending on the product and location from one of our many worldwide locations or from one of our authorized distributors The field engineers are experienced both on Woodward products as well as on much of the non Woodward equipment with which our products interface For field service engineering assistance please contact us via telephone email us or use our website and reference Customer Services and then Technical Support Woodward 49 APECS 500 Electronic Engine Speed Governing System Manual SE 4107 Technical Assistance If you need to telephone for technical assistance you will need to provide the following information Please write it down here before phoning General Your Name Site Location Phone Number Fax Number Prime Mover Information Engine Turbine Model Number Manufacturer Number of Cylinders if applicable Type of Fuel gas gaseous steam etc Rating Application Control Governor Information Please list all Woodward govern
7. the control lever is usually the throttle lever On compression ignition engines diesels the control lever is usually one of the mechanical governor levers either shutoff or governor Linkage The linkage connects the actuator shaft to the engine control lever A good linkage allows for misalignments and contributes to accurate stable and responsive performance with minimal play or friction 4 Woodward Manual SE 4107 APECS 500 Electronic Engine Speed Governing System All purpose Calibration Tool ACT ACT is a PC personal computer based software calibration and monitoring tool ACT is designed specifically for use with engines equipped with the APECS 500 controller The tool can be run on any IBM compatible computer that meets the requirements listed in ACT Installation in Chapter 4 Once the APECS 500 controller has been programmed ACT may be disconnected The APECS 500 unit will continue to operate normally with ACT either connected or disconnected NOTE The scope of this manual does not include selection and installation of speed sensors actuators or linkages that Woodward offers for use with the APECS system Information is available on our website at www woodward com NOTE The need for sub components such as switches and potentiometers is application dependent Please contact Woodward for information specific to your application Woodward 5 APECS 500 Electronic Engine Speed Governi
8. APECS 500 Controller Slow Blow Fuse Power DC 10 amp ES TEY DY GND Pin 1 VBAT Pin 2 Twisted Pair Wire gt 1 twist per inch Figure 3 APECS 500 Wiring Diagram Woodward 9 APECS 500 Electronic Engine Speed Governing System Manual SE 4107 Speed Sensor Installation Magnetic Pickup Wiring Installed opposite an engine driven gear such as the flywheel the mag pickup transmits a signal each time the magnetic flux path across the pole is interrupted by a gear tooth The mounting of the sensor unit must be rigid excessive vibration can Cause erroneous signals and unreliable performance Connect the speed sensor to the two RPM inputs on the controllers Most sensors do not have a positive or negative side and can be connected either way Use twisted pair shielded wire for all soeed sensor wiring The shield should be grounded at the controller only RPM Pin 5 APECS 500 se er ie en ME RPM Pin 6 Figure 4 Speed Sensor Wiring Actuator amp Linkage Installation 1 Select an actuator with sufficient force to move the fuel control lever from minimum to maximum fuel position Make certain that the actuator can reach maximum fuel position when the actuator is warm as some reduction in force may occur The controller has a working range of 9 30 VDC However the actuator must be selected for either a 12 or 24 VDC charging system 2 Select or design a bracket
9. Ed engine speeds aw El error codes awf File name M WiewSetup ax Save as type act View Setup Files avf v Cancel Type in a file name that reflects the purpose of the saved configuration and click Save The view configura tion dialog will now display the se lected file name in the title bar Open Clicking Open will prompt the user for a file name of a previously saved View Configuration Select the desired file and click Open The View Configuration will be updated with the saved parameters 40 Woodward Manual SE 4107 APECS 500 Electronic Engine Speed Governing System The ACT application will always recall the default set of plot configuration parameters at application startup and does not recall the last used view setup file So the view con figuration will always start with the default view Several parameter view screens can be open with different configurations by changing the configuration on the parameter list screen F9 or Open then opening a new Parame ter View NOTE Only one of the parameter view screens can be monitoring the controller at once Configure Menu Configure Serial Port This command allows you to designate the proper COM port for your PC to enable communication between the ACT and the APECS controller To Configure the Serial Port 1 From the main menu screen choose Configure gt Custom ACT Communications Configuration x
10. RUN TIME Run time sec before underspeed is checked O Actuator Initial value for duty Output DUTYCYCLE_OFFSET cycle adjust for 0 25 Calibration improved startup 16 Woodward Manual SE 4107 APECS 500 Electronic Engine Speed Governing System Governor Gain Calibration Parameters PID Gains Adjustment PROPORTIONAL_GAIN INTEGRAL_GAIN and DERIVATIVE GAIN are all multiplied by the master gain from the single turn potentiometer In effect adjusting the master gain adjusts all three PROPORTIONAL GAIN INTEGRAL GAIN and DERIVA TIVE GAIN are preset to values which should permit stable performance on most ap plications To optimize performance all three gains may be individually tuned using ACT It is suggested that the master gain potentiometer be set to the middle of travel before adjusting gains using the ACT Calibration Parameters Requiring Configuration DERIVATIVE GAIN Engine speed governor derivative gain unitless Derivative gain is used to improve stability Increase derivative gain until response has a slight overshoot on load transients INTEGRAL GAIN Engine speed governor integral gain unitless Integral gain is used to remove steady state errors Increase integral gain until speed begins to oscillate and then decrease until oscillation stops If oscillations do not occur bump actuator lever then decrease integral gain until oscillation stops PROPORTIONAL_GAIN Engine speed governor prop
11. Underspeed shutdown immediately shuts off the ac tuator when an underspeed condition is detected Engine speed must be brought back 20 Woodward Manual SE 4107 APECS 500 Electronic Engine Speed Governing System to zero before the actuator is driven again Setting UNDERSPEED_PCNT to zero disables the underspeed protection feature UNDERSPEED TIME Time in msec that an underspeed condition must exist before a fault is latched Default value 2500msec UNDERSPEED RUN TIME Amount of time the engine must be in run mode before underspeed shut down is acti vated seconds How Does Overspeed Work The APECS 500 has the diagnostic capability to detect and react to an overspeed condition The feature uses two programmable parameters OVERSPEED PCNT and OVERSPEED TIME Overspeed feature immediately shuts off the actuator when the engine runs above OVERSPEED PCNT for OVERSPEED TIME OVERSPEED TIME is used to adjust the sensitivity large value will delay the shut down and a small value will hasten it A value as small as zero can be used which means that the first occurrence of engine speed being over OVERSPEED PCNT will result in a shut down This is too sensitive and the engine could be shut down in the unlikely event that noise on the speed signal input caused a high miscalculation of engine speed minimum value of 250 msec is recommended The user should realistically determine an overspeed tolerance time When an overspeed c
12. a2d AUX LAMP INRUSH TIME 4 3 msec 10 AUX OUTPUT 2 RPM 1500 0 700 0 rpm AUX OUTPUT RPM 1501 0 700 0 rpm BRAKE DELAY 1 0 0 0 sec CRANK 2 RUN 1100 0 700 0 rpm CRANK DUTY CYCLE 1 000 0 945 100 DERIVATIVE GAIN 0 262 0 250 NONE DERIVATIVE GAIN IDLE 0 262 0 250 NONE You may select Save to File if you would like to save a permanent record of the file compare You will then be asked to select a destination directory and file name Change APECS Password This command allows you to add or change a password to protect certain calibration features The option is useful for example to prevent unauthorized changes to a known good calibration set in the APECS unit By default the APECS unit is not password protected To Change APECS Password x 1 Choose Calibrate gt Change APECS Password You will be prompted for the current Passwo rd Please enter the controller password E Ehange Cancel OK ae cee E Enter password and click OK 34 Woodward Manual SE 4107 APECS 500 Electronic Engine Speed Governing System 2 The application will x query the controller to verify that the entered password matches the Base Enter Me CONTONE Passion current password If the po password matches the Change button is enabled Er Change Cancel Password Valid Click Thange to change controller password 3 Click Change and the application will prompt for the new password Password Management i i x E
13. conductors on a printed circuit board with your hands or with conductive devices IMPORTANT DEFINITIONS WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION indicates a potentially hazardous situation which if not avoided could result in damage to equipment NOTE provides other helpful information that does not fall under the warning or caution categories Woodward Governor Company reserves the right to update any portion of this publication at any time Information provided by Woodward Governor Company is believed to be correct and reliable However no responsibility is assumed by Woodward Governor Company unless otherwise expressly undertaken O Woodward 2004 All Rights Reserved Manual SE 4107 APECS 500 Electronic Engine Speed Governing System Contents ARRE i ME AAA E ELECTROSTATIC DISCHARGE AWARENBESS ocococcocanononcananoncananoncananoncananancnas 1 CHAPTER 1 GENERAL INFORMATION uavnuvnvnnvnnnnnnnnnnnunnnnunnnnunnnnunnunnnnunnnnunnunn 2 System BaSiCS e on E Anaea Eaa AAE ENA ENN U aa 2 System Components coccccnnccccnncnonccnnnncnnnnnonnnononononononnnnnnnnnnnonnnnnnrnnnnnnnnnnnnnnnnnnnnnnnnnnnos 3 APECS Gontroller a hocico seis 3 IOS CSCS ON PE ES A 4 A A o E O EV 4 LAK sr ral terra epi E 4 All purpose Calibration Tool ACT ccccccsssecceeeceeeeeeeeesaeeeeeeseeseaeeeeeessaaeeeees 5 CHAPTER 2 INSTALLING THE HARDWARE ccococcoc
14. display the file using the default text viewer Convert Cal File to Strategy This command is used to convert old ACT files for use with controllers that have a dif ferent control strategy version ACT will 1 Parse through all of the calibration parameters in the old ACT file 2 Search for the same calibration parameters in the new ACT file and assign values from the old calibration 30 Woodward Manual SE 4107 APECS 500 Electronic Enqine Speed Governing System To Convert a Cal File to a New Strategy 1 Choose File gt Convert Cal File to Strategy 2 ACT will prompt you to enter a name to save the text file Enter a file and click OK ACT will read all of the calibration values from the controller create and save a text file with the parameter names values and units then display the file using the default text viewer Calibrate Menu The Calibrate Menu allows you to perform operations related to APECS calibration The following commands are available e Change APECS Calibration e Download Cal File to APECS e Compare APECS Cal to File Cal e Change APECS Password e APECS Calibration Wizard These commands can be password protected to prevent unauthorized calibration changes See Change APECS Password for more information Change APECS Calibration The Change APECS Calibration command allows you to calibrate configure and adjust various parameters associated with the APECS controller
15. or damaged 6 Use proper gauges and lengths of wire as shown in Table 1 Wire insulation should be appropriate for engine applications Excessive length or inadequate gauge can cause increased wire resistance that can limit the current to the actuator and prevent full actuator travel 6 Woodward Manual SE 4107 APECS 500 Electronic Engine Speed Governing System 7 Increased electrical resistance can also result from poor wiring techniques It is important to use good quality terminations and proper crimping technique during wiring Terminations must be impervious to moisture to prevent shorts and corrosion Wiring Length Excessive resistance in the wiring will result in insufficient force from the actuator Such increased resistance can result from too much wire length inadequate wire gauge or poor connections The following table shows the recommended gauges and maximum lengths of connecting wires for different size APECS actuators Wire length is the total length to and from used to connect the actuator to the controller and the controller to the system power NOTE All system wiring should be twisted pair and shielded preferably foil shielded Table 1 System Wiring ME ETT 50 mm 50 mm ETTE 00 mm 075 66 tt 20m 20 m ESTO 10 m 2267 mM 6 7 m NS 46 ft 14 m 23 ft 7 m 15 ft 4 6 m INT 46 ft 14 m 23 ft 7 m 15 ft 4 6 m The controller has a working range of 9 30 VDC However the ac
16. parameters that are used to properly configure an application Entering incorrect values for these parameters will result in improper configuration and may make the engine run at maximum throttle Entering values outside of safe operating range can result in serious physical injury and or damage to the equipment Woodward 15 APECS 500 Electronic Engine Speed Governing System Manual SE 4107 List of Parameters FAC CATEGORY PARAMETER DESCRIPTION TORY CAL DERIVATIVE_GAIN Speed stability Governor Gain INTEGRAL_GAIN Steady state speed Calibration RAMP_DOWN RATE Engine speed ramp 1000 down rate RAMP_UP_RATE Pa 1000 Maximum engine speed SET SPEED MAX 5000 Engine Set Speed Calibration possible with speed pot Minimum engine speed PEN SER MIY possible with speed pot Er WARMUP PCNT Engine warm up speed WARM UP TIME Time spent at warm up speed No of pulses per engine No of pulses until next engine speed update Speed Input Configuration PULSES PER UPDATE CRANK DUTY CYCLE Kickoff duty cycle for 0 945 a E open loop cranking Percentage of set speed Engine Start Calibration CRANK_2_RUN_PCNT where crank to run tran sition occurs Actuator shutdown OVERSPEED PCNT med OVERSPEED TIME Time in msec before 250 setting overspeed fault Diagnostics UNDERSPEED PCNT Actuator shutdown Time in msec before UNDERSPEED_ TIME setting underspeed fault 2500 speed min UNDERSPEED
17. that correctly aligns the actuator shaft and control lever and is able to withstand the vibration level of the engine or application 3 The linkage must have minimal friction binding and backlash The bracket and linkage should be designed to use as much of the actuator travel as possible 4 Fasten actuator to bracket and bracket to engine Attach necessary linkage between actuator shaft and fuel control lever Move linkage end to end to confirm correct travel and adjust length if needed 5 Connect actuator wires use 7 twisted pair with more than 1 sn twist per inch Actuator travel should be adjusted to assure F both maximum start fuel or ACT Pin 4 rated load and minimum FE shutdown or idle positions ACT Pin 3 Figure 5 Actuator Wiring NOTE It is beyond the scope of this manual to discuss detailed actuator selection and installation procedures for all possible applications Please contact the factory for specific information concerning your application 10 Woodward Manual SE 4107 APECS 500 Electronic Engine Speed Governing System Chapter 3 Calibrating APECS Features A gt eee Calibration Guide This section explains the procedures for calibrating configuring and adjusting the various APECS 500 features to work with your application Before proceeding make sure you have completed the installation of all the required hardware for your system and are familiar with using the Al
18. the APECS permanent memory This is a convenient one step method for e Reverting back to a known good calibration set after experimenting with new calibration settings e Programming multiple APECS units for a particular application The downloaded file may have been previously configured and calibrated for satisfactory engine performance with another APECS unit To Download a Cal File to APECS Choose a Calibration fle to download ET 1 Choose Calibrate gt ane PT Download Cal File to APECS Tr The following screen allows you to select a Cal file to download File name Open Files of type ca Files 000 4 CT y Cancel I Open as read only Calibration File Comments 2 Choose a file and click OK The following screen will show the progress Processing Calibration Values OVERSPEED RPM 32 Woodward Manual SE 4107 APECS 500 Electronic Engine Speed Governing System NOTE During the Download Cal File to APECS operation the user may en counter a situation where the Cal File password is different from that of the APECS unit If this happens please refer to the steps below to complete the download operation To Download a Cal File to APECS with a Password Different from that of the APECS Unit Whenever the APECS password is added or changed the new password is stored in the unit as well as in any calibration file saved after the change During a Download Cal File to APE
19. tool software in use Calibration Process of configuring and adjusting the controller to work with a specific application Calibration Wizard Interactive software guide to help you set up basic calibration and get the controller in operation quickly Control Strategy The version of software residing in the controller Duty Cycle Percentage of time a pulse width modulated pwm signal remains on Parameter Numerical value that helps the user calibrate the APECS controller PWM Pulse Width Modulation Means of simulating analog output with a digital device The PWM duty cycle determines the equivalent analog output the higher the duty cycle the higher the equivalent analog output A PWM signal is used by APECS to drive the actuator Speed Sensor Device such as a magnetic pickup that senses engine speed Woodward 45 APECS 500 Electronic Engine Speed Governing System Manual SE 4107 Chapter 6 Service Options A AE RAS O ee Product Service Options The following factory options are available for servicing Woodward equipment based on the standard Woodward Product and Service Warranty 5 01 1205 that is in effect at the time the product is purchased from Woodward or the service is performed e Replacement Exchange 24 hour service e Flat Rate Repair e Flat Rate Remanufacture If you are experiencing problems with installation or unsatisfactory performance of an installed system the following options are available
20. tripping the fault code will continue to flash the LED This signifies to the user that the engine stopped due to overspeed or underspeed engine conditions The engine may later be restarted without resetting the unit this action will cause the fault code to reset and the LED will then stop flashing Calibration Parameters Requiring Configuration OVERSPEED PCNT Critical engine speed for overspeed protection RPM The overspeed setpoint will be the current set speed plus the overspeed percentage Overspeed RPM Desired RPM 1 OVERSPEED_PCNT Set OVERSPEED_PCNT to zero if overspeed protection is not desired Normal closed loop governing will decrease the duty cycle to the actuator any time engine speed is above the set point Overspeed protection immediately shuts off the actuator when an overspeed condition is detected Engine speed must be brought back to zero before the actuator is driven again Setting OVERSPEED_PCNT to zero disables the overspeed pro tection feature Default value 0 25 OVERSPEED TIME Time in msec that an overspeed condition must exist before a fault is latched Default value 250 msec UNDERSPEED PCNT Minimum engine speed used for underspeed shutdown The underspeed setpoint will be the current set speed times the underspeed percentage Underspeed RPM Desired RPM UNDERSPEED PCNT Normal closed loop governing will increase the duty cycle to the actuator any time en gine speed is below the set point
21. CS operation if the password stored in the calibration file matches the password in the unit ACT will readily download the calibration to the APECS unit However if the password stored in the calibration file does not match the password in the APEGS unit ACT will alert you of a password mismatch Please follow the steps below to complete the download operation 1 When a password mismatch is detected the ACT displays a message Cal File password differs from that of the APECS unit Download the Cal File password to the APECS unit 2 If you answer Yes to this message see note below the calibration file will be downloaded and the password in the APECS unit will be changed to match the password stored in the calibration file 3 If you answer No to this message the calibration file will still be downloaded but the password in the unit will remain unchanged NOTE Before answering Yes to the message make sure you know the password in the calibration file If you do not know the password you will not be able to access the password protected features under the Calibrate menu Please see Change APECS Password command for more information on password protection Compare APECS Cal to File Cal This command lets you check the differences in calibration sets between a saved file and the APECS unit The feature is useful for example to ensure that the saved file matches the calibration in the APECS unit Choose a Ca
22. Comments View Text File Convert APECS Cal to Text Convert Cal File to Text Convert Cal File to Strategy Woodward 27 APECS 500 Electronic Engine Speed Governing System Manual SE 4107 Save APECS Cal to File This command allows you to save APECS calibration data to a designated file The ACT uploads the calibration set from the APECS controller and saves it to a computer file This operation is usually done after the controller has been calibrated for satisfactory engine performance but can also be done at any other time The data is saved ina binary file format that is not readable To Save APECS Cal to File 1 3 Choose File gt Save APECS Cal to File ACT will prompt the path where the file will be saved Select Create File Name to save to i 2 x Enter a file name to save the Ea Ej e calibration data to ACT will automatically append the file extension ACT to the file name if you do not specify one Click Save or press lt Enter gt File name My Cal Fid Save as type cal Files ACT y Cancel A ACT PROGRESS ACT will then read all of the current calibration values from the controller This screen shows the progress Processing Calibration Values PROPORTIONAL_GAIN prompt you to add comments to the ACT file to aid in later identification If you click Yes the comment editor screen will appear To enter commenis type them one at a time and press lt Ente
23. M N Actual RPM J N Add Load TIME TIME Integral gain too low Desired response Woodward 23 APECS 500 Electronic Engine Speed Governing System Manual SE 4107 Chapter 4 ACT Operation AAA ACT Installation ACT Kit Contents The All purpose Calibration Tool ACT is used for programming configuring and adjusting and monitoring the APECS controller with your personal computer The ACT kit contains the following e Software CD ROM e Interface module e RS 232 connecting cable e CD ROM Installation Guide Set up Requirements Hardware Requirements e IBM compatible personal computer equipped with a CD ROM drive and a serial port with DB 9 connector capable of 9600 baud communication e Windows software 95 98 Me 2000 XP e 64 MB of available RAM memory and a hard disk with at least 2 0 megabyte of free disk space e SVGA capable video card and monitor capable of 256 colors and 800 x 600 display Software Requirements CD ROM of calibration tool software to run on your personal computer CD supplied with ACT kit Hardware Set up To connect your PC to the APECS 500 use the cable provided with the calibration tool kit This cable has a DB 9 connector on one end and a four pin white plastic Molex connector on the other end Connect one end of the RS 232 cable to your PC s COM port Connect the other end of the cable to the control module NOTE The APECS 500 must be powered up in order for ACT to opera
24. SE 4107 MW WOODWARD APECS 500 Electronic Engine Speed Governing System User Manual Manual SE 4107 A A WARNING Read this entire manual and all other publications pertaining to the work to be performed before installing operating or servicing this equipment Practice all plant and safety instructions and precautions Failure to follow instructions can cause personal injury and or property damage The engine turbine or other type of prime mover should be equipped with an overspeed shutdown device to protect against runaway or damage to the prime mover with possible personal injury loss of life or property damage The overspeed shutdown device must be totally independent of the prime mover control system An overtemperature or overpressure shutdown device may also be needed for safety as appropriate CAUTION To prevent damage to a control system that uses an alternator or battery charging device make sure the charging device is turned off before disconnecting the battery from the system Electronic controls contain static sensitive parts Observe the following precautions to prevent damage to these parts e Discharge body static before handling the control with power to the control turned off contact a grounded surface and maintain contact while handling the control e Avoid all plastic vinyl and Styrofoam except antistatic versions around printed circuit boards e Do not touch the components or
25. and actuator Each component contributes to the overall performance of the system and shortcomings in any of the components will detract from total system performance Optionally the All purpose Calibration Tool ACT may be used to customize operation APECS Controller The APECS 500 series controller is a single speed electronic engine governor that provides a means of controlling and limiting engine speed by adjusting the fuel control lever with a proportional actuator APECS 500 will maintain fixed engine RPM regardless of load provided that the engine s available power is not exceeded i e isochronous operation The APECS 500 controller has a multi turn potentiometer for speed adjustment and a single turn potentiometer for gain adjustment A serial interface is provided for additional adjustments with the ACT The controller has six Euro style screw terminals for e Battery Positive and Negative 9 30 VDC Reverse voltage protected e Actuator Positive and Negative 6A continuous Short circuit protected e Magnetic Pickup MPU Positive and Negative 2 VAC minimum at 1000 Hz Woodward 3 APECS 500 Electronic Engine Speed Governing System Manual SE 4107 Provided that the MPU frequency is compatible with the engine application setup consists of the following 1 Set gain potentiometer to center of travel 5 The speed set potentiometer should be set to the minimum speed fully counterclockwise position 2 Apply po
26. application and environment data associated with the file 4 ACT will save the calibration set and automatically append the file extension ACT to the file name Calibrating an APECS Unit with a Saved Calibration File You may wish to calibrate additional APECS units with a saved calibration file for consistent optimized operation To Calibrate an APECS Unit with a Saved Calibration File 1 Access the Calibrate Menu to activate the Download Cal File to APECS command 2 Select the appropriate file to download refer to the comment list on the right side of the screen to help identify the desired file Enter password if prompted 3 ACT will download file calibration to APECS permanent memory 4 Repeat Steps 1 and 2 if multiple APECS units are to be calibrated NOTE The APECS unit must be powered up but need not be mounted on the engine to carry out the calibration procedure 14 Woodward Manual SE 4107 APECS 500 Electronic Engine Speed Governing System Understanding APECS Calibration Parameters This section provides answers to frequently asked questions about calibration parameters lists parameters and provides calibration procedures Frequently Asked Questions What is a calibration parameter A parameter is a numerical value that helps the calibrator adjust or set the APECS controller Once fixed by a calibrator the parameter is not subject to change while the system is operating APECS calibration
27. at the time the replacement unit is shipped If the core field unit is returned to Woodward within 60 days Woodward will issue a credit for the core charge The core charge is the average difference between the flat rate replacement exchange charge and the current list price of a new unit Return Shipment Authorization Label To ensure prompt receipt of the core and avoid additional charges the package must be properly marked A return authorization label is included with every Replacement Exchange unit that leaves Woodward The core should be repackaged and the return authorization label affixed to the outside of the package Without the authorization label receipt of the returned core could be delayed and cause additional charges to be applied 46 Woodward Manual SE 4107 APECS 500 Electronic Engine Speed Governing System Flat Rate Repair Flat Rate Repair is available for the majority of standard products in the field This program offers you repair service for your products with the advantage of knowing in advance what the cost will be All repair work carries the standard Woodward service warranty Woodward Product and Service Warranty 5 01 1205 on replaced parts and labor Flat Rate Remanufacture Flat Rate Remanufacture is very similar to the Flat Rate Repair option with the exception that the unit will be returned to you in like new condition and carry with it the full standard Woodward product warranty Woodward Produc
28. ble potentiometers e Set Speed Potentiometer The user may manually adjust engine operating speed using the set speed potentiometer This is a multi turn potentiometer requiring 20 30 turns to cover the full range of operating speeds The potenti ometer has an internal clutch to prevent overturning The range of speeds com manded is adjustable using the ACT Due to the resolution of the internal digital electronics it may not be possible to adjust operation to the exact frequency e g 60 1Hz vs 60 Hz e Master Gain Potentiometer The user may manually adjust control gain using the single turn master gain potentiometer Master gain influences Proportional Integral and Derivative gain The range of gains commanded is adjustable us ing the ACT Woodward 11 APECS 500 Electronic Engine Speed Governing System Manual SE 4107 Provided that the MPU frequency is compatible with the engine application setup consists of the following 1 Set gain potentiometer to center of travel 5 The speed set potentiometer should be set to the minimum speed fully counterclockwise position 2 Apply power to controller The status LED should turn on for one second indicat ing normal operation 3 Crank engine The status LED should turn on continuously indicating a good speed signal from the MPU If not check the MPU installation and wiring If LED immediately begins to flash a two code indicating engine overspeed increase the desired spee
29. ckly as possible To Calibrate a Controller Unit Using the APECS Calibration Wizard 1 Choose Calibrate gt Calibration Wizard 2 The Wizard will give you the option to use the default calibration or modify the existing one If you select the default calibration the Wizard will reset all calibration parameters 3 Press lt Enter gt to continue or lt Esc gt to abort the Wizard If you press lt Enter gt the Wizard will lead you through the calibration process with a series of questions When all questions have been an swered the Wizard will ask you to confirm that the values entered are accurate 4 Press lt Enter gt to confirm the values lt PgUp gt to go back and change the val ues or lt Esc gt to abort the Wizard If you press lt Enter gt the APECS Wizard will download the new calibration and reset all APECS parameters This will complete the APECS Wizard operation NOTE The APECS Calibration Wizard only covers basic calibration It does not automatically assure optimum engine operation Please refer to APECS Calibration Procedures for more information 5 You are now ready to run your engine Press any key to go directly to the Pa rameter Plot screen where you can adjust the PID gains 36 Woodward Manual SE 4107 APECS 500 Electronic Engine Speed Governing System Monitor Menu The Monitor Menu allows you to observe engine and APECS operation in real time The following commands are available under t
30. clothing made of synthetic materials Wear cotton or cotton blend materials as much as possible because these do not store static electric charges as much as synthetics 3 Keep plastic vinyl and Styrofoam materials such as plastic or Styrofoam cups cup holders cigarette packages cellophane wrappers vinyl books or folders plastic bottles and plastic ash trays away from the control the modules and the work area as much as possible 4 Do not remove the printed circuit board PCB from the housing unless absolutely necessary If you must remove the PCB from the housing follow these precautions e Do not touch any part of the PCB except the edges e Do not touch the electrical conductors the connectors or the components with conductive devices or with your hands e When replacing a PCB keep the new PCB in the plastic antistatic protective bag it comes in until you are ready to install it Immediately after removing the old PCB from the control cabinet place it in the antistatic protective bag CAUTION To prevent damage to electronic components caused by improper handling read and observe the precautions in Woodward manual 82715 Guide for Handling and Protection of Electronic Controls Printed Circuit Boards and Modules Woodward 1 APECS 500 Electronic Engine Speed Governing System Manual SE 4107 Chapter 1 General Information AAA RA A A A a a System Basics APECS 500 is a single speed electronic
31. commanded engine speed ACT PULSES PER UPDATE SET SPEED MIN SET SPEED MAX 7 A mori E 33 XOX oo data into the APECS or the ACT Entering values outside of safe operating range The APECS 500 is a user configurable engine speed governor and will follow your settings and commands immediately It is possible to enter values in the APECS module that are in excess of what the engine is capable of performing and outside of safe operating range It is the user s responsibility to pay attention when entering can result in serious physical injury and or damage to the equipment or application 22 Woodward Manual SE 4107 APECS 500 Electronic Engine Speed Governing System Step 6 Step 4 Step 5 Calibrate the selected gt Adjunt Don features by configuring de INTEGRAL E arameters if needed the listed parameters 3 PROPORTIONAL GAIN RAMP DOWN RATE Engine Cranking Default RAMP UP RATE WARMUP PCNT CRANK DUTY CYCLE 0 95 WARMUP TIME CRANK 2 RUN PCNT 0 90 Overspeed Underspeed Protection TN OVERSPEED IPCNT e UNDERSPEED_PCNT UNDERSPEED_RUN_TIME TIME TIME Integral gain too high or derivative gain too low PID Gains too high Actual RPM N Desired RPM E Desired RPM Actual RPM TIME TIME PID Gains too low ia a too I Remove Load Desired RP
32. d Actual RPM F Ny Add Load Figure 11 Integral Gains Too High or Figure 12 Desirable Response Derivative Gains Too Low NOTE Excessive friction and slop in the linkage are primary contributors to poor governor stability If it is not possible to stabilize engine performance check smoothness of the linkage Engine Set Speed Calibration Parameters The following calibration parameters require configuration RAMP_DOWN_RATE Rate at which command engine speed decreases from one set point to a lower set point RPM second RAMP_UP_RATE Rate at which commanded engine speed increases from one set point to a higher set point RPM second SET SPEED MAX Highest engine speed command possible with set speed potentiometer SET SPEED MIN Lowest engine speed command possible with set speed potentiometer 18 Woodward Manual SE 4107 APECS 500 Electronic Engine Speed Governing System WARMUP_PCNT Engine speed set point used immediately after engine has started running RPM WARMUP_TIME Length of time to hold engine at warm up speed immediately after engine has started running seconds Setting WARMUP_TIME to zero disables the warm up feature Speed Input Configuration Parameters The following calibration parameters require configuration PULSES PER UPDATE The number of pulses received by the controller between engine speed calculations and updates The fewer the pulses the faster the update rate and the lower the resolution t
33. d setting by turning the multi turn speed set potentiometer sev eral turns clockwise Repeat this crank and adjust process until the engine starts 4 Adjust speed setpoint until desired speed is achieved If the engine speed will not settle down turn the gain potentiometer counterclockwise until stable perform ance results 5 Once the desired speed setpoint is achieved adjust gain for optimal performance at all loads In general this amounts to increasing the gain as much as possible without inducing oscillation under any load 6 If additional fine tuning is required connect the ACT and adjust All purpose Calibration Tool Set up To connect your PC to the APECS 500 use the cable provided with the calibration tool kit This cable has a DB 9 connector on one end and a four pin white plastic Molex con nector on the other end Connect one end of the RS 232 cable to your PC s COM port Connect the other end of the cable to the control module NOTE The APECS 500 must be powered up in order for ACT to operate For further information on installation and operation of the All purpose Calibration Tool ACT refer to Chapter 4 Connector Molex 39 01 2040 Terminals Molex 39 00 0039 JE att tt ACT Harness COMPUTER Female DB 9 Figure 6 ACT System Set up 12 Woodward Manual SE 4107 APECS 500 Electronic Engine Speed Governinq System Calibration Categories To incorporate any of the programmable features in
34. e Consult the troubleshooting guide in the manual e Contact Woodward technical assistance see How to Contact Woodward later in this chapter and discuss your problem In most cases your problem can be resolved over the phone If not you can select which course of action you wish to pursue based on the available services listed in this section Replacement Exchange Replacement Exchange is a premium program designed for the user who is in need of immediate service It allows you to request and receive a like new replacement unit in minimum time usually within 24 hours of the request providing a suitable unit is available at the time of the request thereby minimizing costly downtime This is also a flat rate structured program and includes the full standard Woodward product warranty Woodward Product and Service Warranty 5 01 1205 This option allows you to call in the event of an unexpected outage or in advance of a scheduled outage to request a replacement control unit If the unit is available at the time of the call it can usually be shipped out within 24 hours You replace your field control unit with the like new replacement and return the field unit to the Woodward facility as explained below see Returning Equipment for Repair later in this chapter Charges for the Replacement Exchange service are based on a flat rate plus shipping expenses You are invoiced the flat rate replacement exchange charge plus a core charge
35. edeciszendadtetecesstsniacsssvedadocistasessbes 26 Running the ACT Software ccccccssssecccecsssseeeeeeeeeeeeeeeeeeeeeeeeeeseaeeeeeessageeeees 26 Progress Display Sr 26 Moving Around the SWAG ocacion 26 ACT Menus amp OPTIONS ooocccccncccccccconccnnnnncnnnnonnncnnnnnnonononnnnnnnnnnnnnnnnnennnnnnnnnnananenoss 27 ACT Menu SIT CIITO Lasses tica 27 PENE 27 Woodward i APECS 500 Electronic Engine Speed Governing System Manual SE 4107 FULD OS arrene 27 Save APECS Cal to File rrrnnnnnnnnnnnnnnnnnnnnnnnnnvnnnnnnnnnennennnnnnnennnnnnnnnnennennnnuene 28 View CA FIEGonmmens ao 29 View Toxt FE ae ER 29 CONVENT COMINO eto o on ellos eh NEO e oe 30 Convert APECGOS CallO Tira oc 30 Convert GaliFile to Td dee dde O 30 Convert Cal File to Strategy ccccccoconconccocoonconnncnnancnnonononncnnnnonannnnnononanenns 30 Cala Men eee ere er e bd pe ade dd 31 Change APECS Calibration ooccccccccnncnnncccnoncnnnnonnancnnnnononnnononononcnnncnnnannnns 31 Download Cal File to APEC S vecinas o 32 Compare APECS Cal to File Cal ccccoconncnnccccconcnncnononncnnononancnnnononanenns 33 Change APEGS Password ass 34 APEGS Gallbration Naar 36 MOMOr Me S REE E de ida cis 37 Parameter VIS Wa corras rbd 37 ParametenPlO usage ne na 38 Display Ir 0 EEE ER 39 Control SEE SPE 40 Pamela 40 Contigure MENU aa 41 Contiqure senal go RE EE 41 HOME RE ME RE 42 PINS ee 42 FEN 0160 ET EEE er eee Co eee oem ae 42 Vri uesecadso
36. eived between timer ticks is discarded 2 Clicking OK will save this information in the Windows Registry so that it will be remembered the next time the program is started NOTE The Calibration Wizard will automatically set up the plots if there are no saved defaults Display Faults This command allows you to display present faults in real time This means if new faults occur while you are monitoring the screen will automatically update to display the cur rent faults The display will also show historical fault codes that have been TE previously logged but do not currently A ea exist Historical fault codes are helpful rnem mek when tracking down intermittent faults od ng fault flags 11 dummy 2 2 fault To Display Faults in Real Time Historical Faults 1 Choose Monitor gt Display Clear Historical Faults Faults from the main menu The application will launch the Fault view The application will update the display every time the controller sends the fault_flags status This happens several times a second Woodward 39 APECS 500 Electronic Engine Speed Governing System Manual SE 4107 2 Click on the Pause button to stop the automatic update of this screen The text on the button will change to Start and clicking it again will re start the automatic updating NOTE If any other screen requests data from the controller while this screen is updating this sc
37. engine governor that combines the convenience of manual TE adjustments with the flexibility of a computer based nisjer A calibration tool Electrical connections consist of six wires to battery actuator and magnetic engine speed pickup via a Euro style terminal strip For most applications APECS 500 can be connected and adjusted with simple hand tools For more advanced features the calibration tool provides user friendly access As shipped from the factory APECS 500 can be manually adjusted for stable operation on most applications that supply a mag pickup frequency of 2500 to 5000 Hz Optionally the user may attach the standard APECS calibration tool ACT to gain access to a number of user adjustable features including e Frequency Range 200 15 000 Hz e Synchronized speed sampling e Proportional Integral and Derivative gains Gain potentiometer affects all three e Overspeed shutdown and delay e Underspeed shutdown and delay e Crank to run transition speed e Warmup speed and time e Startup gains e Offset to actuator command e Battery voltage compensation In the event of a fault APECS 500 provides helpful diagnostic information with an on board status lamp Additionally the ACT may be used to access current and historic fault codes APECS is an acronym for Advanced Proportional Engine Control System It provides a means of controlling engine speed by adjusting the fuel control leve
38. he greater the pulses the greater the averaging effect on calculated engine speed Factory set to zero Optimal performance is generally obtained by setting PULSES PER UPDATE 2 PULSES PER REV number of engine cylinders Setting PULSES PER UPDATE 0 will provide the fastest update rate but may detract from performance PULSES PER REV The number of teeth on the engine speed pickup wheel mag pickup input and Hall Effect sensor or the number of spark pulses per engine rev ignition input To figure out the pulses per revolution you must determine the kind of speed signal input used on your application Magnetic Pickup Input or Hall Effect Sensor Pulses per revolution number of teeth on the flywheel Woodward Mini Gen Signal Generator Pulses per revolution 0 5 x drive ratio if Mini Gen is driven at other than crankshaft speed If readout is desired in Hz instead of RPM set PULSES PER REV 60 This may detract from performance PULSES PER REV is factory set to 60 Engine Start Calibration Parameters The engine cranking parameters control how APECS will drive the actuator during cranking The following calibration parameters require configuration CRANK_2 RUN_PCNT Speed transition point indicating engine has gone from crank mode to run mode RPM This transition is a percentage of the desired RPM commanded by the multi turn poten tiometer Crank 2 Run RPM Desired RPM CRANK 2 RUN PCNT Once engine RPM ri
39. he Monitor Menu e Parameter View e Parameter Plot e Display Faults e Control Strategy e Parameter List Parameter View This command allows you to view certain operating variables i e engine speed in real time To View Parameter Values in Real Time 1 Choose Monitor gt Parameter View The application will launch 215 the view screen Name Value Unts engine rpm 399 4 rpm n desired 2560 6 rpm St tpc_dutycycle 0 09439 NONE Stop app_norm 0 43771 NONE 2 The screen automatically starts Configure reading values from the controller and displaying the values 3 To stop the updating click on Stop The button name will then change to Start Clicking it again will start updating again NOTE If any other screen is opened that requires communication with the controller while the screen is updating the Parameter View screen will be automatically stopped Woodward 37 APECS 500 Electronic Engine Speed Governing System Manual SE 4107 Parameter Plot The Parameter Plot command lets you view engine performance on screen in the form of a real time graph This feature allows you to perturb the system and observe the response to fine tune engine performance To View Parameter Plot in Real Time Select Monitor gt Parameter Plot The application will launch and start the parameter plot view fal Parameter Plot dd The application will read the previously saved configuration and request t
40. he controller to start sending the parameter values The controller sends the data to the PC at a rate that varies with the number of parameters being monitored The application uses the Windows timer functionality to update the screen at the specified rate Note that if the Time 5 1 0 Sec per division PC is very busy the timer accuracy will vary therefore the screen and generated data files should be considered as Je reference only engine rpm rpm f 576 142 engine_speed rpm fi 525 000 The X axis time scale 25 seconds in the example screen may be shorter than config ured due to the resolution of the monitor This value will be adjusted when the graph is resized This also applies to the print functionality for this screen All of the data will be recorded in a revolving buffer for use by the Save to File feature see below The axis scales parameter names update resolution and time scale on the Parameter Plot may be changed as described in the Plot Setup screen PID Gain Adjustments from Plot Display Screen After initial calibration most engines require only a minor adjustment to PID gains to fine tune the system to its optimum level ACT provides a convenient means of adjust ing the PID gains directly from the Plot Display screen To Make PID Gain Adjustments from Plot Display Screen 1 Press the letter lt P gt for proportional lt l gt for integral or lt D gt for deriva tive gain adju
41. k case ground Make sure linkage moves freely without backlash Check tip of speed sensor Check parameter settings Check linkage and the actuator travel Ensure that load is not greater than engine capacity Engine speed unusually low Actuator disonnected open circuit or short circuit If calibration file is available download calibration Factory y file and cycle power again settings lost If controller still does not work or if no calibration file is available consult factory Defaults to minimum Consult factory speed Consult factory Electrical noise may be entering controller Check wiring shielding and connections to controller Cycle power to engine If controller still does not work consult factory Check actuator wiring and actuator resistance Resistance should be less than 10 ohms Yes Yes Yes Yes es Speed set pot out of range Controller unit failed 44 Woodward Manual SE 4107 APECS 500 Electronic Engine Speed Governing System Glossary of Technical Terms ACT All purpose Calibration Tool Software PC software program for configuring and calibrating the APECS controller Actuator Device that converts an electrical signal from the APECS controller to an output shaft position APECS Advanced Proportional Engine Control System Engine governing system developed by Woodward Cal File File containing APECS calibration data Cal Tool Version The version of calibration
42. l purpose Calibration Tool ACT See Chapter 4 for details on ACT Engine speed and master gain can be calibrated manually without using the ACT by adjusting the two potentiometers on the front of the APECS 500 controller Optimal performance is best achieved by using the ACT to individually adjust Propor tional Integral and Derivative gains More advanced features are also accessible by using the ACT If APECS 500 is to be used on a variety of engines or applications it may be possible to develop unique calibrations for each one download before installation and then do any fine tuning using the manual adjustments Safety Precautions The APECS 500 is a user configurable engine speed governor and will follow your settings and commands immediately Please be aware of this when calibrating and entering values in the unit It is possible to enter values in the APECS unit that are in excess of what the engine is capable of performing and outside of safe operating range It is the user s responsibility to be accurate when entering data into the APECS or the ACT Entering values outside of safe operating range can result in serious physical injury and or damage to the equipment or application WARNING An overspeed shutdown device independent of the APECS system should be provided to prevent loss of engine control that may cause personal injury or equipment damage Manual Calibration APECS 500 is equipped with two manually adjusta
43. libration file to compare 2x1 To Compare APECS Cal to File Cal Look in E Desktop e a c EE 1 Choose File gt Compare APECS Cal to File Cal This screen allows you to select a Cal File to compare Files of type Cal Files 000 4CT y Cancel Open as read only Calibration File Comments Woodward 33 APECS 500 Electronic Engine Speed Governing System Manual SE 4107 2 Choose a file and Click OK This screen will show the progress Processing Calibration Values OVERSPEED_RPM 3 Once all parameters have been processed a ACT x message box will list the compare results If the parameters in the file match the controller the AN SE EE following message box appears 4 Click OK to close If there were mismatches the following message will appear Compare Differences EI Controller lt gt C WWOODVARDNACT TOOLNAPX41MOSTEST ACT Mismatch List Nane File Controller Units ACTUATOR_FDBK_GAIN 0 20001 0 72498 NONE ACT FDBK KFILT 0 801 0 977 NONE AFB LOST DLY 21 20 ms 10 AFB NO AMPS 33000 D m APP AD ORH 254 1023 adcnts APP AD ORL 10 0 adents APP FULL DEADBAND 6 5 adents APP IDLE DEADBAND 6 5 adcnts APP_MIN_CAL 230 0 240 5 adonts APP_NOISE_CNT 31 30 NONE APP RANGE CAL 550 0 540 5 adcnts AUTOCRANK CRANK TIME 11 0 10 0 sec AUTOCRANK MAX TRIES 5 6 NONE AUTOCRANK NS TIME 1 0 1 5 sec AUTOCRANK REST TIME 16 0 15 0 sec AUXILIARY OUTPUT 2 MODE 1 0 NONE AUXILIARY OUTPUT MODE 2 D NONE AUX I LIM 121 120
44. ng System Manual SE 4107 Chapter 2 Installing the Hardware A Eee Take adequate protection to ensure personal and equipment safety and follow the suggested installation sequence given below Install main components Review Wiring page 6 Controller page 8 Speed Sensor page 10 Actuator amp Linkage page 10 Wiring Guidelines APECS 500 has six Euro style terminals for external connections To use 1 Loosen the terminals with a small blade screwdriver 2 Strip wire 3 Insert wire into terminal hole 4 Tighten terminal with a small blade screwdriver Guidelines 1 Refer to Figures 2 amp 3 and Tables 1 amp 2 to install the system and subcomponents 2 Mount the unit in a location where the effects of vibration and temperature are within the specified range Operating temperature 40 F to 185 F 40 C to 85 C vibration 6 G s from 40 to 2000 Hz See Figure 2 for controller dimensions 3 Power leads are to be connected directly to a switched power source i e battery Use of a 10 amp slow blow fuse is recommended in the battery positive wire 4 Use shielded cable for external speed signal source Shields should be connected to the battery ground wire at one end only 5 Use of convoluted tubing conduit or other wire shielding is recommended to minimize the likelihood of mechanical damage to wires Avoid routing wires near sharp edges or near locations that can cause the wires to be pinched
45. nter new Password cod OK Status Password Change Mode 4 Enter the new password It should be one word no spaces and up to 11 characters long Once entered click OK The application will prompt to re enter the password to make sure that it was typed in properly 5 Re enter the password and click ERRE OK If the two entries of the new password are equal the new password will be encoded and Re enter new password saved in the controller Passwords are upper and lower case Fange eee sensitive Status Password Change Mode o After changing your password please record it in a safe place for future reference To revert to no password protection change APECS password to peg which is the de fault password ACT Operation with the New Password Once a password is added or changed the following calibration features become password protected Change APECS Calibration Download Cal File to APECS Change APECS Password APECS Calibration Wizard At the start of any future sessions ACT will always prompt you to enter the new pass word to gain access to these features You only need to enter the password once during any session to gain access to all the password protected features Woodward 35 APECS 500 Electronic Enqine Speed Governinq System Manual SE 4107 APECS Calibration Wizard The APECS Calibration Wizard is an interactive guide to help you get your controller unit up and running as qui
46. ol Confirm that the load e g voltage regulator on generator is not inducing instability Try adjusting the gains to achieve stability Fault Codes The APECS 500 controller is capable of identifying certain fault conditions and alerting the user to them A flashing LED indicates the fault conditions The current fault code list is shown in Table 6 Please note the following 1 When power is first applied to the controller the LED will flash just once for one second to indicate that the LED is working If there are multiple faults the LED will flash them all in sequence Count the flash codes to determine the fault conditions or connect the calibration tool to observe the fault conditions Use the Display Faults option under the Monitor Menu If there are no faults the LED will flash once at reset and from then on indicate the detection of engine speed continuous ON LED indicates that a valid engine speed is being sensed The controller will attempt to shut down for some faults and will not permit starting after reset with faults 1 5 and 8 Woodward 43 APECS 500 Electronic Engine Speed Governing System Manual SE 4107 Table 6 Fault Codes ENGINE FAULT CORRECTIVE ACTION APECS unit not Calibrate PULSES PER REV calibrated ves Check parameter settings Overspeed criteria may be too sensitive Check for electrical noise entering controller Engine speed Check wiring and connections excessive Chec
47. oncoconcononcanoncannaranonrancarannnn 6 Wing CNS go PP a 6 Wining ge 7 Controller Installation scada indi 8 Controller WiriNgQ cocooconncnncccconncnncnononcnnncnnnnncnnnononnnconnnonnnncnnnnnnnnrnnnnnnnnnnoss 8 COP ONG ag JG barrera MN 9 Speed Sensor Install OM ae 10 Magnetic Pickup Wiring cccooocccnccccnnncccnccnnonononnnnoncnnonnncononnnncnnononcnnonnnnnncnnas 10 Actuator amp Linkage Installation cocoooncccccconnnccconnnnoconconononnnnconanonconancnnnnnos 10 CHAPTER 3 CALIBRATING APECS FEATURES annuennnnnnvnnnnnnnnnnnnennnnnnennnnnner 11 eo AO MNOS PA 11 Safety Precautions cccccccccccsssseceeeceeseeceeceaeeeeesesaueeeessseeeeeeesseeeseeeessaaees 11 Manual Calibration cccccccccccccsssseeeceeeeeeeeeeeeeceeeeesseeeeseeeeeeesseaeaeeeeeeeeensaas 11 All purpose Calibration Tool Set UP oooccccccccocccnncccnooncononononnconononancnnnnnnnannons 12 Calibration Categories cccccccccoconnnccnnnccconononnccnnnnnononnnnncnnnnnonononannnnnnnnnnnnnnnos 13 Calibrating aa PES UN asus 13 Saving a Calibration Set to File coonocnnnccnnncccccoconncnnnnncnonononncnnnnnonnnnnnos 14 Calibrating an APECS Unit with a Saved Calibration File 14 Understanding APECS Calibration Parameters oooonccnncccnocccnncnnnoncnnnonnnanennnnnnnns 15 Frequently Asked QUEStiONS ooococccooonncccncnnnnnnnnnnccnononnnnnnnnnnnnnnnnnnnnnnnnnnnnss 15 List Of Parameters
48. ondition is detected the duty cycle goes immediately to zero This should stop the engine or at least drive it to minimum speed A fault code is generated and the LED flashes The fault will continue to flash so that the user is made aware of why the engine stopped The engine may be restarted without resetting the unit The fault will then recover and stop flashing By default overspeed is disabled This is because a properly tuned PID governor will decrease the duty cycle to the actuator any time engine speed is above the set point 50 ordinarily overspeed is not necessary It is disabled by setting OVERSPEED PCNT to zero However if a user feels the need for a more aggressive response to an overspeed condition the overspeed diagnostic feature may be used Actuator Output Calibration Parameters The following calibration parameter requires configuration DUTYCYCLE OFFSET The total PWM duty cycle output to the actuator is the sum of the Proportional Integral and Derivative branches plus an offset term DUTYCYCLE OFFSET The integrator is always reset to zero at startup Setting DUTYCYCLE OFFSET to a non zero value helps the transition from crank to run modes Default value is 0 3 Woodward 21 APECS 500 Electronic Engine Speed Governing System Manual SE 4107 Calibration Setup amp Configuration Parameters Flowchart jer Step 2 KE Setup the APECS Configure speed input alibrate the range 0 Calibration Tool PULSES PER REV
49. ors actuators and electronic controls in your system Woodward Part Number and Revision Letter Control Description or Governor Type Serial Number Woodward Part Number and Revision Letter Control Description or Governor Type Serial Number Woodward Part Number and Revision Letter Control Description or Governor Type Serial Number If you have an electronic or programmable control please have the adjustment setting positions or the menu settings written down and with you at the time of the call 50 Woodward Manual SE 4107 APECS 500 Electronic Engine Speed Governing System NOTES Woodward 51 We appreciate your comments about the content of our publications Send comments to icinfo woodward com Please include the manual number from the front cover of this publication MW WOODWARD PO Box 1519 Fort Collins CO 80522 1519 USA 1000 East Drake Road Fort Collins CO 80525 USA Phone 1 970 482 5811 e Fax 1 970 498 3058 Email and Website www woodward com FM 57982 BS EN ISO 9001 1994 6 March 2001 en ran rr oO r J Woodward has company owned plants subsidiaries and branches as well as authorized distributors and other authorized service and sales facilities throughout the world Complete address phone fax email information for all locations is available on our website 04 9 M
50. ortional gain unitless Proportional gain is used to improve response time maximum amount of proportional gain should be used while still maintaining stability Increase proportional gain until speed begins to oscillate then decrease until oscillation stops If oscillations do not occur bump actuator lever then decrease proportional gain until oscillation stops PID Gain Settings Response Plots ACT allows the user to adjust the P I and D gain settings and observe the response directly on screen in the form of a real time plot The plots on the following page illustrate the various conditions a user may encounter while tuning an application Although conditions may vary according to application and nature of load these plots are typical of what is often observed Figures 7 11 illustrate less desirable conditions often encountered while tuning an application and suggest probable causes Figure 12 shows a plot of a properly tuned application Although conditions may vary according to application and nature of load this plot is typical of what is often desired Woodward 17 APECS 500 Electronic Engine Speed Governing System Manual SE 4107 Desired RPM Se Desired RPM N Actual RPM P F Actual RPM TIME Figure 7 PID Gains Too Low Figure 8 PID Gains Too High i Actual RPM Desired RPM N Actual RPM A Desired RPM Figure 9 Integral Gains Too Low Figure 10 Derivative Gains Too High Desired RPM XY Remove Loa
51. parameters are used not only to adjust and set the controller but also to configure it properly for different applications Why do we need to calibrate the APECS system APECS 500 can be both manually and computer adjusted APECS 500 is factory pro grammed for operation between 2500 and 5000 Hz MPU frequency and with P 1 D gains that should permit stable performance on the majority of applications For optimal performance calibration with ACT may be required Do I need to calibrate ALL the parameters to make my system work No All parameters are preset to values that will work with many engines and applica tions However it is recommended that you review all settings for your own application Is it possible to enter values in APECS in excess of what the application is capable of performing Yes While ACT the calibration tool restricts you from entering values outside of the specified range the range itself is fairly wide and it is possible to enter values in excess of what your application is capable of performing For example it is possible to command engine speeds up to 8192 RPM with ACT Your engine may or may not be able to operate at this speed It is also possible to damage the generator or pump attached to your engine by commanding maximum engine speed because while the engine may be capable of performing at the rated RPM the generator or pump is likely to have a lower RPM rating than the engine Furthermore there are certain
52. pic through an alphabetical listing or by typing in a word or phrase 3 Follow the on screen commands to page through the manual About ACT This command displays the version of the calibration tool that you are currently using This information is important for tool identification purposes and for servicing support User s Manual This command accesses the User s Manual which includes comprehensive information on the APECS 500 controller wiring diagrams ACT software menus and calibration parameters The manual may be viewed online or printed for future reference 42 Woodward Manual SE 4107 APECS 500 Electronic Engine Speed Governing System Chapter 5 Troubleshooting SSS ee General Checklist Please follow the checklist below to troubleshoot your APECS controller We recommend using a digital multimeter capable of measuring frequency and duty cycle such as a Fluke 87 1 Check battery voltage for stability and correct value The LED will turn on for one second when the APECS 500 is first powered up For magnetic pickups check that the speed signal is at least 2 Vms using the AC volt settings on voltmeter Actuator should go to full travel during cranking The LED will illuminate when it senses an engine speed Check the actuator linkage for binding and backlash Check that the actuator has sufficient force to reach the starting and rated load positions Confirm normal operation of engine under manual contr
53. r gt or click Save Edit You can re edit comments by clicking them changing the text on the top line and clicking Save Edit Comments can be deleted by clicking on them and then clicking Delete or by pressing lt Del gt 28 Woodward Manual SE 4107 APECS 500 Electronic Engine Speed Governing System 4 Click OK on the comment editor or press lt Enter gt twice to save comments Click Cancel or press lt Esc gt twice to close the window without saving comments The Cal File will still be created if the comment editor is canceled 5 The following message is displayed when the file is created successfully The file name in this message is the file selected in Step 2 ACT will save the calibration data to the designated file and display Calibration Data Saved in File ABCD ACT message where ABCD is the name you entered in Step 2 NOTE The Save APECS Cal to File command stores the calibration data as an ACT file that cannot be viewed or printed directly Viewing and printing must be done from a converted text file See Convert APECS Cal to Text and Convert Cal File to Text commands View Cal File Comments This command allows you to display the comments that are attached to a calibration file Users add comments when saving a calibration file The comments help in tracking specific engine application and environment data for which the calibration file was created To View Calibra
54. r with an actuator The heart of the system is a powerful microcontroller that processes the signal received from a speed sensor and compares it to the desired speed setting The output of the controller is a pulse width modulated PWM signal that drives a precision proportional actuator connected to the engine s fuel control lever The actuator converts the signal to an output shaft position proportional to the duty cycle of the pulse width modulated signal APECS 500 provides isochronous engine governing i e engine speed is maintained at the commanded setting regardless of load through a wide speed range APECS is suitable for use on both compression ignition diesel and spark ignition gasoline CNG LPG engines Woodward Manual SE 4107 APECS 500 Electronic Engine Speed Governing System A Woodward developed the APECS system for a variety of on and off highway applications Typical applications include generator sets compressors construction machinery and farm vehicles WARNING An overspeed shutdown device independent of the APECS system should be provided to prevent loss of engine control that may cause personal injury or equipment damage APECS 500 Controller Pk Cutpul Gain P Programmable parameters speed Figure 1 APECS Engine Control System System Components The three components required to install an APECS 500 governor on an engine are the APECS 500 controller speed sensor
55. reen will automatically Pause Control Strategy This command allows you to check the version of the control strategy in use This information may be needed for strategy identification purposes and for future updates Parameter List The Parameter List screen allows the user to adjust which parameters are displayed on the Parameter View display To Display the Parameter List 1 Choose Monitor gt Parameter List from the main menu 2 The F5 F6 keys will backup advance through the list Press F9 or click on On View List to toggle the selected parameter on the Parameter View screen Parameter List bg max gine mo 3 Click on the box in the ti tle bar or press lt Esc gt to close the screen Edits are not saved between applica tion launches lamp flash cntr lamp timer FSJPREVIOUS F6 NEXT FS ADD REMOVE ON VIEW ESC CANCEL EDIT CLOSE e 4 Ifthe Parameter View Cal File Name Demc 000 prom_t eeprom write attempts ngine mode n conversion factor Pen PP View List Information On View List View Position a Open Save screen Is already open when changes are made to the view list close the Parameter View screen and re open it to make the changes effective Save Clicking Save will prompt the user for a file name to save the currently viewed configuration to Choose or create a file to save the view setup bo E a Save in act qe ft CF
56. rvice Department 1 800 523 2831 in North America or 1 970 482 5811 They will help expedite the processing of your order through our distributors or local service facility To expedite the repair process contact Woodward in advance to obtain a Return Authorization Number and arrange for issue of a purchase order for the item s to be repaired No work can be started until a purchase order is received NOTE We highly recommend that you make arrangement in advance for return shipments Contact a Woodward customer service representative at 1 800 523 2831 in North America or 1 970 482 5811 for instructions and for a Return Authorization Number Replacement Parts When ordering replacement parts for controls include the following information e the part number s XXXX XXXX that is on the enclosure nameplate e the unit serial number which is also on the nameplate How to Contact Woodward In North America use the following address when shipping or corresponding Woodward Governor Company PO Box 1519 1000 East Drake Rd Fort Collins CO 80522 1519 USA Telephone 1 970 482 5811 24 hours a day Toll free Phone in North America 1 800 523 2831 Fax 1 970 498 3058 For assistance outside North America call one of the following international Woodward facilities to obtain the address and phone number of the facility nearest your location where you will be able to get information and service Facility Phone N
57. ses above Crank 2 Run RPM it is assumed that the engine is in run mode Default value is 0 9 Woodward 19 APECS 500 Electronic Engine Speed Governing System Manual SE 4107 CRANK_DUTY_CYCLE The fixed duty cycle used to drive the actuator when the engine is cranking percent May be calibrated to a maximum duty cycle for diesel engines that require full rack for starting or a minimum duty cycle for some spark ignition engines that require closed throttle for starting In run mode control is closed loop the actuator is driven as neces sary to maintain the set desired speed NOTE Default Value is 0 95 which will work with most engines and applications Enter ing new values for these parameters is optional Diagnostics Calibration Parameters Overspeed Underspeed Protection The overspeed protection feature shuts off the actuator when the engine runs above the overspeed RPM Setting the OVERSPEED_PCNT value to zero disables this feature The underspeed protection feature shuts off the actuator when the engine RPM runs under the overspeed RPM Set the UNDERSPEED_RUN_TIME value as desired Setting the UNDERSPEED RPM value to zero disables the underspeed protection feature When an engine overspeed underspeed condition is detected the engine protection control logic causes 1 the actuator duty cycle to go immediately to zero and 2 a fault code activation that is signified by LED flashing After engine protection control logic
58. stment The application will enable the gain you selected 2 Use the Up or Down arrow keys to increase or decrease the present value The arrow keys adjust the values by 0 004 New values may be typed in directly Hit lt Enter gt after you type in a value The application will save the new value in the APECS unit 3 Press lt Esc gt to deselect the gain adjustments To Change Plot Setup This allows you to choose engine RPM desired engine speed duty cycle or any other parameter for viewing real time plots on screen Axis scales can also be adjusted to fit the parameter and or speed 38 Woodward Manual SE 4107 APECS 500 Electronic Engine Speed Governing System 1 Onthe Parameter Plot screen click on Configure The application will show the following screen with the current values Plot Setup xj Plot 2 engine speed h Avis Max Axis Maz 900 Asie Min Anis Min f 400 Asis Time Scale 20 sec Number Vertical Divisions 11 Ose Sample Rate 250 m sec Humber Horizontal Divisions ii Open Save Cancel Plot 1 Plot 2 Use the pull down to select the desired parameter to plot Axis Min Max Enter the minimum maximum value for the parameter value X Axis Time Scale Controls how much data is displayed on the X axis This value may automatically adjust for screen resolution X Axis Sample Rate Controls how often the data from the controller is used to update the screen Data rec
59. t and Service Warranty 5 01 1205 This option is applicable to mechanical products only Returning Equipment for Repair If a control or any part of an electronic control is to be returned to Woodward for repair please contact Woodward in advance to obtain a Return Authorization Number When shipping the item s attach a tag with the following information name and location where the control is installed name and phone number of contact person complete Woodward part number s and serial number s description of the problem instructions describing the desired type of repair CAUTION To prevent damage to electronic components caused by improper handling read and observe the precautions in Woodward manual 82715 Guide for Handling and Protection of Electronic Controls Printed Circuit Boards and Modules Packing a Control Use the following materials when returning a complete control protective caps on any connectors antistatic protective bags on all electronic modules packing materials that will not damage the surface of the unit at least 100 mm 4 inches of tightly packed industry approved packing material a packing carton with double walls a strong tape around the outside of the carton for increased strength Woodward 47 APECS 500 Electronic Engine Speed Governing System Manual SE 4107 Return Authorization Number When returning equipment to Woodward please telephone and ask for the Customer se
60. t the APECS controller is powered up and connected to the computer s COM port 2 Ifan icon for the calibration tool exists double click on it to start the ACT software The license screen will be displayed when the ACT is launched You must either accept the terms or Cancel which exits the application License Agreement Copyright E 2004 Woodward Inc This software and the accompanying witten matenals are copyrighted This software may not be copied in whole or m part regatdless of the form of media without prior written consent of Woodward Inc Woodward Inc makes no warranties express or implied with respect to the software or its qualty performance merchantability or fitness for any particular purpose The software ts koensed and delivered as is Any damages loss of property or other costs resulting from the use of this software is the sole responsibility of the indridual or organization using E 3 If no icon exists click on the Start button highlight Programs find the ACT software and click to start it Default is Woodward then select APECS EPS Calibration Tool 4 Make sure the COM port designation in ACT matches the serial port on the back of your PC 5 Follow the procedure outlined in the Configure Menu to change the COM port assignment if needed Progress Display Screen This screen is intended to inform the user of the progress of time consuming communi ca
61. tacsstaoesacicamce tes seen cuceeteentes 42 CHAPTER 5 TROUBLESHOOTING anaunnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnvnnnnuenunnr 43 General CHECKS E EE EAEE A AE EAEE EE 43 ero 0 fal 0 0 aa a dd id a a 43 Glossary of Technical Terms a a 45 CHAPTER 6 SERVICE OPTIONS nannnnnnnnnnnnnnnnnnnnnnnnnunnnnnnunnnnnnunnvnnnunnvnunvnnenen 46 Product Service Options RS 46 Replacement EXC snuse 46 Fat io cn A EN 47 Flat RATE REM SNAUE nn te et 47 Returning Equipment for Repair ccccsecccccsseeeeceeeeeeeceseeesaeeeeeeeeeeessaeeessaeeees 47 Pekar 47 Return Authorization Number escri a e SSS 48 Replacement FS Lae 48 How to Contact Woodward rrannnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnennnnnnnennennnnannnnnennnnennennnnuene 48 Engineering Sei ES tias 49 TEMME ASS ANE did 50 li Woodward Manual SE 4107 APECS 500 Electronic Engine Speed Governing System Electrostatic Discharge Awareness All electronic equipment is static sensitive some components more than others To protect these components from static damage you must take special precautions to minimize or eliminate electrostatic discharges Follow these precautions when working with or near the control 1 Before doing maintenance on the electronic control discharge the static electricity on your body to ground by touching and holding a grounded metal object pipes cabinets equipment etc 2 Avoid the build up of static electricity on your body by not wearing
62. te 24 Woodward Manual SE 4107 APECS 500 Electronic Engine Speed Governing System Connector Molex 39 01 2040 Terminals Molex 39 00 0039 ACT Harness COMPUTER Female DB 9 Figure 13 ACT System Set Up Software Set Up ACT software can be automatically installed on your hard drive from the CD ROM supplied with the kit To install the software follow the procedures below NOTE Close all applications to prevent possible conflict between the ACT installer and other programs 1 Turn on your computer and insert the ACT disk into the CD ROM drive The install program should automatically launch If it does not open Windows Explorer go to the CD ROM drive and double click on the install program 2 Follow the prompts from the install program You may select the default directory or specify your own 3 When installation is complete you may access the ACT software from the Start Menu or create your own shortcut 4 The set up is now complete and you are ready to run ACT e Torunthe ACT software please refer to Running the ACT Software in the following section e Put the original CD ROM in a safe place in case the files on your hard drive become damaged or lost Woodward 25 APECS 500 Electronic Engine Speed Governing System Manual SE 4107 Basic ACT Operation Running the ACT Software The ACT software is fairly easy to use Follow the procedures below to run the program 1 Make certain tha
63. tion Comments Select a Calibration file and its comments are displayed be 2 x Look in 4 Desktop e amp e Edy 1 Choose File gt View Cal File Y My Documents Comments Mee My Network Places CAD System Files ACT will display a list of files on the left joemo o00 side of the screen with file comments on the right File name 2 Use the Up and Down arrow keys to Files oftype CalFiles 000 ACT Clse highlight the desired calibration file T Open as readonly ACT extension and view the comments attached to that file Calibration File Comments 3 Click OK or Cancel to close Comment Viewer The comments are created or edited when the files are created View Text File This command is a convenient way to view text files Choose File gt View Text File ACT will prompt for a text file to view Select a file and click OK ACT will open the selected file with the default viewer for that file type a dl E Woodward 29 APECS 500 Electronic Engine Speed Governing System Manual SE 4107 Convert Commands The Save APECS Cal to File command discussed earlier stores the calibration data as an ACT file that cannot be viewed or printed directly Viewing and printing must be done from a converted text file There are two convert commands available with ACT Convert APECS Cal to Text and Convert Cal File to Text The difference between the two commands is as follows
64. tion procedures It will close automatically when the procedure is complete Pitra Cab ken ab EE FAULTS 1 Moving Around the Software There are five main menu items available with ACT Several options are available under each main menu item The discussion in the following pages assumes the cursor is at the main menu screen e Use mouse to select or move around the menu e Use left mouse to execute a command or accept a condition e Use function key lt F1 gt for HELP e A HOT key highlighted character in a menu item can also be used to access or activate a menu or sub menu e g File use lt ALT gt lt F gt e Click on the x box in the upper right hand corner to exit ACT 26 Woodward Manual SE 4107 APECS 500 Electronic Enqine Speed Governing System ACT Menus amp Options ACT Menu Structure ACT s five main menus File Menu Calibrate Menu Monitor Menu Configure Menu and Help Menu have several options available under each A complete discussion of all ACT menus and options is presented in the following pages Save APECS Cal to File View Cal File Comments View Text File FILE MENU Convert APECS Cal to Text Convert Cal File to Text Convert Cal File to Strategy HE MONITOR MENU File Menu Purpose The File Menu allows you to perform operations related to viewing saving and converting files The following commands are available under the File Menu Save APECS Cal to File View Cal File
65. tuator must be selected for either 12 or 24 VDC charging system Woodward 7 APECS 500 Electronic Engine Speed Governing System Manual SE 4107 Controller Installation Controller Wiring The controller can be installed in the engine compartment maximum temperature 185 85 C 2A DES sou v 9 uy IDA Z Ea Usk E BL Lt AR IYA LOY LOY Wd Hdy 4 00 101 6mm a mn o JO EEE E MW WOODWARD 0 175 4 4mm _APECS co 2 places pr gt BE GOYERVOR Sie ER mon 1 12 28 5mm 0 88 22 3mm Figure 2 APECS 500 Dimensions Table 2 Controller Wiring FUNCTION PIN INFORMATION ACT Pm ACT Pi VBAT on 2 GND in Speed Signal Input RPM Pin 5 RPM Pin 6 ACT Connector RCV Pin 4 TXD Pin 3 GND2 Pin 1 Woodward Manual SE 4107 APECS 500 Electronic Engine Speed Governing System Controller Pinout Use the diagram below to connect your APECS controller to battery power the mag pickup actuator and ACT Calibration Tool Setup Magnetic Pickup RPM Pin 5 y ta Twisted Pair Shielded Wire A RS 232 Cable shield grounded at controller only Female DB 9 Gnd Pin 5 TXD Pin 2 RCV Pin3 Twisted Pair Wire gt 1 twist perinch ACT Pin 3 Proportional Actuator Output I 7 act en 4 Molex 39 01 2040 pil Ay Gnd Pin 1 TXD Pin 3 ROV Pin 4 Speed Set i Master Gain
66. umber Brazil 55 19 3708 4800 India 91 129 230 7111 Japan 81 476 93 4661 The Netherlands 31 23 5661111 You can also contact the Woodward Customer Service Department or consult our worldwide directory on Woodward s website www woodward com for the name of your nearest Woodward distributor or service facility For worldwide directory information go to www woodward com ic locations 48 Woodward Manual SE 4107 APECS 500 Electronic Engine Speed Governing System Engineering Services Woodward Industrial Controls Engineering Services offers the following after sales support for Woodward products For these services you can contact us by telephone by email or through the Woodward website e Technical Support e Product Training e Field Service Contact information Telephone 1 847 967 7730 Email info_niles woodward com Website www woodward com ic Technical Support is available through our many worldwide locations or our authorized distributors depending upon the product This service can assist you with technical questions or problem solving during normal business hours Emergency assistance is also available during non business hours by phoning our toll free number and stating the urgency of your problem For technical support please contact us via telephone email us or use our website and reference Customer Services and then Technical Support Product Training is available at many of our worldwide locations
67. wer to controller The status LED should turn on for one second indicat ing normal operation 3 Crank engine The status LED should turn on continuously indicating a good speed signal from the MPU If not check the MPU installation and wiring If LED immediately begins to flash a two code indicating engine overspeed increase the desired speed setting by turning the multi turn speed set potentiometer sev eral turns clockwise Repeat this crank and adjust process until the engine starts 4 Adjust speed setpoint until desired speed is achieved If the engine speed will not settle down turn the gain potentiometer counterclockwise until stable perform ance results 5 Once the desired speed setpoint is achieved adjust gain for optimal performance at all loads In general this amounts to increasing the gain as much as possible without inducing oscillation under any load Speed Sensor APECS 500 monitors engine speed continuously using a magnetic pickup MPU which detects the passing of teeth on an engine driven gear e 9 flywheel The frequency of the voltage generated by the MPU is proportional to engine RPM Actuator The actuator converts a pulse width modulated signal received from the controller to an output shaft position proportional to the duty cycle of the pulse width modulated signal The actuator is mounted on the engine and connected to the control lever by a mechanical linkage NOTE On spark ignition engines
68. your system a set of parameters associated with each feature must be calibrated using the calibration tool ACT These parameters are grouped under various categories under the Calibrate Menu in ACT Refer to Table 3 below Table 3 Calibration Categories and Features CALIBRATION CATEGORY FEATURES AVAILABLE Engine Set Speed Range of commanded speeds Calibrating an APECS Unit Once the system set up is complete it is fairly easy to calibrate an APECS 500 controller Before proceeding with calibration please ensure that the controller unit is connected to the COM port and powered Follow the steps below for calibrating your APECS controller unit 1 Ifan icon for the calibration tool exists double click on it to start the ACT software 2 If no icon exists click on the Start button highlight Programs find the ACT software and click to start it 3 Make sure the COM port designation in ACT matches the serial port on the back of your PC Follow the procedure outlined in the Configure Menu to change the COM port assignment if needed 4 The Wizard is an interactive guide to help you get your controller running as quickly as possible If you wish to use the Wizard for basic calibration refer to APECS Calibration Wizard in Chapter 4 5 If you do not use the Wizard calibrate the speed input for the type of speed sensor PULSES PER REV and PULSES PER UPDATE Refer to Speed Input Configuration Parameters

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