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DSS-2 Two-Channel Digital Speed Switch

1. File name My Data ACT Files of type Cal Files 000 ACT M Close Open as read only Calibration File Comments 1 BSS 2 Calibration for 8 engine 2 Channel 1 Crank Disconnect at 700 rpm 3 Channel 2 Engine Overspeed Protectionn at 2000 rpm A 5 Engine Protection enabled E 7 Greg Pence 7 15 05 Woodward 31 DSS 2 Two Channel Digital Speed Switch Manual 36598 2 Use the Up and Down arrow keys to highlight the desired calibration file ACT extension and view the comments attached to that file 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 E e e Convert Commands The Save DSS 2 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 DSS 2 Cal to Text and Convert Cal File to Text The difference between the two commands is as follows 1 In Convert DSS 2 Cal to Text operation the calibration set that is converted is from the DSS 2 unit 2 In Convert Cal F
2. Clicking it again will start updating again NOTE As shipped from the factory n_desired will actually be in units of Hz not rpm as indicated When PULSES PER_REV 60 n_desired will display in Hz To display actual rpm change PULSES DER REN and PULSES PER_UPDATE to equal the actual number of gear teeth per engine revolution 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 44 Woodward Manual 36598 DSS 2 Two Channel Digital Speed Switch 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 ke Parameter Plot E i The application will read the previously saved configuration and request the 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 s 1 0 Sec per division PC is very busy the timer accuracy will vary therefore the scree
3. 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 Woodward 57 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 W 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 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 05 8 M
4. repeated until either the engine starts or AUTOCRANK_ MAX_TRIES cycles have been performed 8 Ifthe cycle has been repeated AUTOCRANK_MAX_TRIES times the autocrank process will be terminated and a fault generated 18 Woodward Manual 36598 DSS 2 Two Channel Digital Speed Switch A typical autocrank installation is shown below In this installation Channel 1 is configured as an overspeed shutdown switch that will interrupt power to the ignition coil when an overspeed threshold is exceeded Channel 2 is configured as an autocrank controller that will energize the starter motor when the Start Switch is turned on Additionally an oil pressure switch and water temperature switch are connected in parallel to the engine protection EP input Slow Blow Fuse F Siow Blow Fusa Siow Dkw Fuge 10 amp 10 amp b 1 3 F Crank Relay ition Kall Relay Twisted Fair Shielded Wire shield grounded at controler anly DES Coniraller Water Temp Reser Gil Pressure F Swich Swich Figure 5 Typical Autocrank Installation Manual Calibration Calibration is best done with a frequency generator to simulate the engine speed input and a frequency meter A zero crossing input of 2 Vac minimum is required Setup consists of the following 1 Set autocrank potentiometer to maximum frequency fully clockwise potentiometer will click at end of travel 2 Apply power to controller All three LEDs should turn on for one
5. 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 communication procedures It will close automatically when the procedure is complete Press ty Cii hin ait EE_FauLts_1 28 Woodward Manual 36598 DSS 2 Two Channel Digital Speed Switch 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 AHOT 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 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 DSS 2 Cal to File View Cal File Comments View Text File F
6. Menu or create your own shortcut 4 The set up is now complete and you are ready to run ACT e Torun the 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 27 DSS 2 Two Channel Digital Speed Switch Manual 36598 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 that the DSS 2 LE controller is powered up and connected to the computer s C O M This software and the accompanying witten matenals ae copyrighted po rt This software may not be copied in whole or in part Copyright C 2004 Woodward Inc regatdless of the form of media without prior written consert of Woodward Inc 2 Ifan icon for the calibration cringed ih espe to the sla ore quay i ormance merc _ ot fitness for any particula tool exists double click on it to Gees The e let Soave oral dated anav start the ACT software The SE of the individual or organization using license screen will be displayed when the ACT is launched You must either Ga eer eae ee ree accept the terms or Cancel Geet which exits the application OO 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
7. With the relay engergized there should be continuity between the C and NO contacts and no continuity between C and NC contacts Relays can be damaged due to excessive currents Always remember to attach a suppression diode across large inductive loads 5 Confirm that all external loads are functioning properly and continuity exists in the wiring harness Fault Codes The DSS 2 controller is capable of identifying certain fault conditions and alerting the user to them A flashing green LED indicates the fault conditions The current fault code list is shown in Table 2 Please note the following 1 When power is first applied to the controller the green LED will flash just once for one second to indicate that the LED is working 2 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 3 If there are no faults the LED will flash once at reset and from then on indicate the detection of engine speed A continuous ON LED indicates that a valid engine speed is being sensed 4 The controller will attempt to shut down for some faults and will not permit Starting after reset with faults 4 and 16 50 Woodward Manual 36598 DSS 2 Two Channel Digital Speed Switch Table 2 Fault Codes Engine rom has exceeded Channel 1 Set Condition speed
8. a means to configure the DSS 2 controller for specific engines applications and environments 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 the following pages All adjustments are stored immediately in non volatile memory in the DSS 2 unit The DSS 2 controller will retain the changes even if power is lost or the ACT is disconnected To Change DSS 2 Calibration Parameters 1 Choose Calibrate gt Change DSS 2 Calibration Set the View Filter to select a group of parameters Use the mouse to scroll through the list SZ WN To change the highlighted parameter Enter the new value in the New Value field Press lt Enter gt The new value is written to the controller and then read back with the result placed in the DSS 2 Value field 5 Press lt Esc gt to exit 34 Woodward Manual 36598 DSS 2 Two Channel Digital Speed Switch Calibration Categories To incorporate any of the programmable features in 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 1 be
9. 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 DSS 2 Digital Speed Switch 2 Channel Two channel speed switch developed by Woodward with both manual and computer adjustable settings Parameter Numerical value that helps the user calibrate the DSS 2 controller Speed Sensor Device such as a magnetic pickup that senses engine speed 52 Woodward Manual 36598 DSS 2 Two Channel Digital Speed Switch Chapter 7 Service Options 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 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
10. all the required hardware for your system as discussed in Chapter 2 Manual Calibration DSS 2 is equipped with two operator adjustable potentiometers one for each channel These are multi turn potentiometers that require 20 30 turns to cover the full range of setspeeds The potentiometers have an internal clutch to prevent damage from overturning The function of the potentiometer will vary depending on how the DSS 2 is configured Calibration with ACT ACT All purpose Calibration Tool can be used to provide a wide variety of custom features to the DSS 2 Refer to Chapter 5 for general information regarding installation connection and operation of ACT The Calibration Wizard is the preferred approach to ACT calibration but similar results can be obtained using the Calibrate Change DSS 2 Calibration Menu item see Chapter 5 for details ACT is not required as long as the channels have been previously configured as desired by the user To launch the Calibration Wizard 1 Select Calibrate then Calibration Wizard www woodward com W woopwarp ko For APECS 500 APECS 3000 APECS 4000 APECS 4500 APECS 5000 EPS 1000 and bss 2 Software Copyright 2006 Al Rights Reserved Calibration Tool 7 3 12 Woodward Manual 36598 DSS 2 Two Channel Digital Speed Switch DSS 2 Calibration Wizard Welcome to DSS 2 Wizard an interactive guide to getting your DSS 2 up and running as quickly and easily as possibl
11. channel System Components The two components required to installa DSS 2 on an engine are the DSS 2 controller and magnetic pickup MPU speed sensor Both components contribute to the overall performance of the system and shortcomings in either will detract from total system performance Optionally the All purpose Calibration Tool ACT may be used to customize operation DSS 2 Controller DSS 2 contains a powerful microcontroller that processes the signal received from the MPU sensor and compares it to the speed setpoints Output control is accomplished by means of two independently controlled form C relays with Common C Normally Closed NC and Normally Open NO contacts Ss SS Gab lew gt Ki ES Ka d s de ES amp Be The DSS 2 controller has two multi turn potentiometers for speed setpoint adjustment A computer serial interface is provided for additional adjustments with the ACT The controller has thirteen Euro style screw terminals for e Battery Positive and Negative 9 30 Vdc Reverse voltage protected e Two form C relays 10A continuous Independent Common C Normally Closed NC and Normally Open NO contacts are provided DSS 2 is factory programmed for standard relay logic relay de energized below set speed but may be modified with the ACT for reverse relay logic relay energized below set speed External diodes should be added for transient suppression with inductive loads
12. distributor or service facility Woodward 55 DSS 2 Two Channel Digital Speed Switch Manual 36598 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 1 970 482 581 1 Toll free Phone in North America 1 800 523 2831 Email icinfo woodward com Website www woodward com 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 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
13. holding MPU position fixed tighten lock nut Hand turn the engine one complete revolution to confirm that none of the gear teeth contact the MPU Connect the speed sensor to the two rpm inputs on the controller 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 DSS 2 requires a minimum output voltage of 2 Vac It is recommended that the MPU output not be shared with other devices tachometers etc Figure 4 Speed Sensor Wiring The frequency of the signal coming out of the MPU is related to the engine rom as follows Frequency Hz RPM X nteeth 60 Where nteeth is the number of teeth on the gear adjacent to The MPU usually the flywheel Conversely RPM frequency X 60 nteeth Many hand held digital multi meters can measure signal frequency Hz Woodward 11 DSS 2 Two Channel Digital Speed Switch Manual 36598 Chapter 4 Calibration Ke Calibration Guide This section explains the procedures for calibrating configuring and adjusting the various DSS 2 features to work with your application Each of the two DSS 2 channels can be independently configured as e Speed Switch either normal or reverse acting e Autocrank Controller e Glow Plug Controller Each of these will be addressed separately Before proceeding make sure you have completed the installation of
14. lt Enter gt Save as lype CAL Fies CACT sl Cancel ACT PROGRESS K ACT will then read all of the current calibration values from the controller This screen shows the progress Processing Calibration Values PROPORTIONAL_GAIN x Once all the values are read ACT will prompt you to add comments to oa S the ACT file to aid in later el Do vou wish to edit the new Cal File Comments identification 30 Woodward Manual 36598 3 DSS 2 Two Channel Digital Speed Switch Cal File Comment List If you click Yes the comment editor screen will appear Cal File Name C Woodward ACT 7_3 My Data AC DSS 2 Calibration for VH engine Channel 1 Crank Disconnec t at 700 rpm Channel 2 Engine Overspeed Protectionn at 2000 rpm Engine Protection enabled To enter comments type them one at a time and press lt Enter 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 Delete AddAsNew SaveEdt CancelEdit 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 The following message is displayed when the file is created succ
15. 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 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
16. to the User s Manual for a complete discussion of features and calibration procedures The final screen presents a signoff message Select Finish to complete the calibration process Click Finish to return to the main menu Woodward 25 DSS 2 Two Channel Digital Speed Switch Manual 36598 Chapter 5 ACT Operation ACT Installation ACT Kit Contents The All purpose Calibration Tool ACT is used for programming configuring and adjusting and monitoring the DSS 2 controller with your personal computer The ACT kit contains the following e Software CD ROM 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 DSS 2 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 Please note that the DSS 2 serial communication port is for service and programming o
17. upper and lower case pp SE Change Cancel sensitive Password Change Mode After changing your password please record it in a safe place for future reference To revert to no password protection change DSS 2 password to peg which is the default password ACT Operation with the New Password Once a password is added or changed the following calibration features become password protected Change DSS 2 Calibration Download Cal File to DSS 2 Change DSS 2 Password DSS 2 Calibration Wizard At the start of any future sessions ACT will always prompt you to enter the new password to gain access to these features You only need to enter the password once during any session to gain access to all password protected features 42 Woodward Manual 36598 DSS 2 Two Channel Digital Speed Switch DSS 2 Calibration Wizard A The DSS 2 Calibration Wizard is an interactive guide to help you get your controller unit up and running as quickly as possible To Calibrate a Controller Unit Using the DSS 2 Calibration Wizard 1 Choose Calibrate gt Calibration Wizard or select the tool button shown above 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 c
18. 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 56 Woodward Manual 36598 DSS 2 Two Channel Digital Speed Switch 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 governors 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
19. wire Electrical loads attached to the two relays should be separately fused MPU Wiring Use shielded cable for MPU signal The shield should be connected to the battery ground wire at one end only Output Loads Channel 1 and Channel 2 output relays may be connected to a variety of electrical loads including starter relays engine ignition systems fuel shutdown solenoids indicator lamps hydraulic solenoid valves etc The current requirements of the load must be matched to the contact capability of the output relays 10A resistive load When the output relays are connected to inductive loads e g solenoids external diodes should be added to increase contact life and for transient suppression Electrical loads attached to the two relays should be separately fused Excessive resistance in the wiring will result in reduced current to the electrical load Such increased resistance can result from too much wire length inadequate wire gauge or poor connections Total wiring length between battery power and the DSS 2 as well as between the DSS 2 and the load must be considered Woodward 7 DSS 2 Two Channel Digital Speed Switch Manual 36598 lt is important to use good quality terminations and proper crimping technique Switch Inputs The switch inputs VER RST EP draw very little current less than 1 mA each The external switches should be selected for prolonged use at these low currents One side of the switch should be conne
20. 000 E Ls501m01 000 E apx41c04 000 Sijapx4imos oo0 E pEMo4000 000 a Cal File to compare E aPx4cos o00 E aPx4Pos oo0 m DEmo4500 000 zua i APX41C06 000 aPx51501 000 E oemosooo o00 E s55511m03 000 File name My Data ACT Files of type CalFiles 000 ACT ei Cancel Dpen as read only Calibration File Comments 1 DSS 2 Calibration for 8 engine 2 Channel 1 Crank Disconnect at 700 rpm 3 Channel 2 Engine Overspeed Protectionn at 2000 rpm A 5 Engine Protection enabled 7 Greg Pence 7 15 05 40 Woodward Manual 36598 DSS 2 Two Channel Digital Speed Switch 2 Choose a file and Click OK Thi s screen will show the Processing Calibration Values progress OVERSPEED_RPM 3 Once all parameters have been processed a message box will list the compare results If the parameters in the file match the controller the following message box appears File Matches Controller 4 Click OK to close If there were mismatches the following message will appear Compare Differences Controller lt gt C WOODWARDSACT 7_3 LSS01M01 000 Mismatch List Name File Controller Units CHNL_1 CONFIG 00010000 00000001 NONE CHNL_ 2 CONFIG 00010000 00000001 NONE EE_FAULTS_1 ooo00000 00001000 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 DSS 2 Password This com
21. 2 Two Channel Digital Speed Switch Chapter 3 Installation CAUTION A Take adequate protection to ensure personal and equipment safety and follow the suggested installation sequence given below Refer to Figures 2 amp 3 and Table 1 to install the system and subcomponents DSS 2 Mounting 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 DSS 2 Wiring DSS 2 has thirteen 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 Refer to Figure 3 Use proper wire gauges 18 AWG 1 mm minimum All wire insulation should be appropriate for engine applications Terminations must be impervious to moisture to prevent shorts and corrosion 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 or damaged Power Leads Power leads are to be connected directly to a switched power source i e battery With both channels on DSS 2 draws a maximum of 100 mA Use of a slow blow fuse is recommended in the battery positive
22. Debounce Time msec to a non zero value To detect an absent speed input If a channel is configured as a speed switch which latches a fault on loss of speed signal it is possible to detect a missing speed signal without having first seen a valid speed signal Set Loss of Speed Signal time sec to a non zero value Once battery power is applied to the VER switch input Start Switch the Loss of Speed Signal logic expects to see a speed signal with this amount of time Completing Wizard Configuration DSS 2 Calibration Wizard L After configuring the Engine Review your selections and click Next to calibrate the controller P rotect O n n p ut 7 th W iza rd Desaipion T Sekcion Unis presents a summary page The Gs Se on of S user should confirm all settings Charne T Mar St Speed SND and use the lt Back button to Channel Resat Percentage 0 79999 correct any discrepancies Channel 2 Configuration Normal Speed Switch Channel 2 Reset Type Automatic Reset on of S Channel 2 Max Set Speed S0000 Sg SEH D After reviewing the summary click Se ET D0 on Next gt to download the values Protection Run Time 0 0 ek 2 to the DSS 2 lt Back Cancel DSS 2 Calibration Wizard The DSS 2 Calibration Wizard is complete For further calibration you may use the Calibrate Change DSS 2 Calibration option To display variables such as engine speed in real time you may use the Monitor Parameter View option Please refer
23. Figure 4 Typical Speed Switch Installation 14 Woodward Manual 36598 DSS 2 Two Channel Digital Speed Switch Manual Calibration Calibration is best done with a frequency generator to simulate the engine speed input and a frequency meter A zero crossing input of 2 Vac minimum is required Setup consists of the following 1 Set potentiometers to maximum frequency fully clockwise potentiometer will click at end of travel 2 Apply power to controller All three LEDs should turn on for one second indicating normal operation 3 Turn on frequency generator and set to desired frequency The green status LED should turn on continuously indicating a good speed signal from the generator 4 Adjust speed setpoints until desired set speeds are achieved Red LEDs should illuminate when set speeds are reached 5 Install DSS 2 on engine and confirm MPU input with engine running Confirm speed switch operation If concerned about overspeeding the engine or load attach 12 volts to the verify VER input Soeed switching will occur at 70 of the actual set speed The range of setspeeds commanded 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 1 Hz vs 60 Hz The wider the range the coarser the resolution Speed Switch Calibration Using ACT The All purpose Calibration Tool ACT can be used to provide a wide variety o
24. ILE MENU Convert DSS 2 Cal to Text Convert Cal File to Text Convert Cal File to Strategy Change DSS 2 Calibration SS MONITOR MENU CONFIGURE MENU Configure Serial Port Help Topics HELP MENU About ACT Woodward 29 DSS 2 Two Channel Digital Speed Switch Manual 36598 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 e Save DSS 2 Cal to File e View Cal File Comments e View Text File e Convert DSS 2 Cal to Text e Convert Cal File to Text e Convert Cal File to Strategy Save DSS 2 Cal to File This command allows you to save DSS 2 calibration data to a designated file The ACT uploads the calibration set from the DSS 2 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 in a binary file format that is not readable To Save DSS 2 Cal to File 1 Choose File gt Save DSS 2 Cal to File Select Create File Name to save to ACT will prompt the path where the file will be saved Svein QQACT730 o E Gator_co6 ACT E 5D0113D ACT 2 Enter a file name to save the calibration data to ACT will automatically append the file extension ACT to the file name if you D n My Daa S do not specify one Click Save or ooo ME press
25. RAL INFORMATION csscecnececnecuccecneceeneceeneceesecusceeasnenens 1 MOUCHO EE 1 How Speed Switches Work cccccccccsseseeeeeceeeeeeeeeeeeeeeeeeeeaeeeeeeeeseeeeeeeesssaeeeeeeesaaees 2 SEa E e E E E E EE A E E E E ET 2 Normal vs Reverse Relay og 2 alen 3 Glow re d a sssusa Ei E 3 EE 3 Bote Eege 3 All purpose Calibration Tool WCTI 5 CHAPTER 2 SPECIFICATIONS ceccsccecnscecnececnecesnecuscecueneeusceeneceeeecusceeuenesaess 6 FNS CU CA EE 6 IEC IMG eri E E E E E 6 CHAPTER 3 INSTALLATION enken KKN KKK KEEN R KENNEN KN RER KEREN KEEN KEEN REENEN D DSS 2 Oe lt Le E 7 BES e E ege eege eg deeg ege 7 alte C PIM OU EE 10 Speed Sensor Installation cccccccssesseccceeeeceeseeeceeeeeeeeeeseeceeeeeseeeeeeeceeeeessaaeeeess 11 CHAPTER 4 CALIBRATION cccccecsececnecnececnececnececnecuececneceeneceenecescecnenesueas 12 INO OOS E 12 Manual Calibration ccccccccccecccsssseeeeeeeeeeeaeseeseceeeeeeseaeeseeeeeeeessaaeeeeeeeeeeeesaas 12 Calibration with ACT RE 12 Speed Switch Confguraton 14 Figure 4 Typical Speed Switch InstallationManual Calibration 14 Manual Calibration cccccccccecccsssseeeeeeeeeeseeeseeeceeeeeeseeeeeseeeeeeessuaeeeeeeeeeeessaas 15 Speed Switch Calibration USING ACTA 15 Normal Operation vs Reverse Operation 16 Reset Mode AutoiManual l atch 16 Speed Switch Optons 16 Speed Switch OPH OMS resides tinetictemsicatatnnaicatateuswats den suatatenace sierdinedaila
26. 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 Woodward 53 DSS 2 Two Channel Digital Speed Switch Manual 36598 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 Product 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
27. W WooDWARD User Manual Oe onenei VW woonowarRpD DSS 2 DSS 2 Two Channel Digital Speed Switch Manual 36598 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 In systems where large inductive loads are switched on the DC power buss surge impulse energy will be present due to the switching To address surge energy affects on the control appropriate suppression devices must be installed in the DC power buss prior to the control s power connection Electronic controls contain static sensitive parts Observe the following precautions to prevent damage to thes
28. Woodward 3 DSS 2 Two Channel Digital Speed Switch Manual 36598 e Magnetic Pickup MPU Positive and Negative 2 VAC minimum at 1000 Hz The controller is factory programmed for 2500 to 5000 Hz This range may be modified with the ACT to cover 200 15 000 Hz or operate in units of rom e Reset Switch Input RST A switch to battery positive switch input is provided for manual reset functions DSS 2 is factory programmed for automatic reset at 80 of set speed but may be modified with the ACT for manual or latched reset e Engine Protection Switch Input EP A switch to battery positive switch input is provided for connection to external engine protection devices e Verify Switch Inout VER A switch to battery positive switch input is provided for a verify function Activating this switch will reduce both channel set frequencies to 70 of their normal values The VER input also functions as a Start Stop switch input in certain modes of operation When a channel is configured as an autocrank controller the Verify switch is used to initiate the start sequence If a channel uses the Verify switch as a Start Switch removing the switch input will force the channel to a set Status Use insulated automotive grade wiring minimum 18 AWG or 1 mm for all connections Shielded wiring is recommended for the MPU The DSS 2 is equipped with three LEDs one green and two red All LEDs will be turned on for one second following power up as a lamp te
29. al File to Strategy This command is used to convert old ACT files for use with controllers that have a different 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 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 DSS 2 calibration The following commands are available e Change DSS 2 Calibration e Download Cal File to DSS 2 e Compare DSS 2 Cal to File Cal e Change DSS 2 Password e DSS 2 Calibration Ward Cl These commands can be password protected to prevent unauthorized calibration changes See Change DSS 2 Password for more information Change DSS 2 Calibration The Change DSS 2 Calibration command allows you to calibrate configure and adjust various parameters associated with the DSS 2 controller Woodward 33 DSS 2 Two Channel Digital Speed Switch Manual 36598 DSS 2 is a programmable speed switch Changing DSS 2 calibration parameters is
30. alibration process with a series of questions When all questions have been answered 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 values or lt Esc gt to abort the Wizard If you press lt Enter gt the DSS 2 Wizard will download the new calibration and reset all DSS 2 parameters This will complete the DSS 2 Wizard operation NOTE Gi The DSS 2 Calibration Wizard only covers basic calibration It does not automatically assure optimum engine operation Please refer to DSS 2 Calibration Procedures for more information Woodward 43 DSS 2 Two Channel Digital Speed Switch Manual 36598 Monitor Menu The Monitor Menu allows you to observe engine and DSS 2 operation in real time The following commands are available under the Monitor Menu Parameter View Parameter Plot Display Faults Control Strategy Parameter List Parameter View This command allows you to view certain operating variables e engine speed in real time To View Parameter Values in Real Time 1 Choose Monitor gt Parameter View The application will launch the view screen E Parameter View engine_rpm set_speed_1 SCC The screen automatically o e P starts reading values from the cheanna DR controller and displaying the values To stop the updating click on Stop The button name will then change to Start
31. ards Evaluations other than specific testing were performed to cover e EN 12895 2000 e EN 61000 6 2 2001 e EN 61000 6 4 2001 Testing to EN 14982 1998 and application specific installation requirements cover evaluations See Chapter 1 of this manual for intended usage of this unit EMC Limitations All cabling for these controllers is limited to less than 3m 9 84 Power cabling is limited to less than 10m 32 8 in total length See wiring diagrams for specific cable types required Declaration of Conformity The official Declaration of Conformity is available upon request Please see the How to Contact Woodward section in Chapter 7 to request a copy Woodward lil DSS 2 Two Channel Digital Speed Switch Manual 36598 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 Avoid the build up of static electricity on your body by not wearing clothing made of synthetic materials Wear cotton or cotton blend materials as much as possible because these do not store s
32. bration is best done with a frequency generator to simulate the engine speed input and a frequency meter A zero crossing input of 2 Vac minimum is required Setup consists of the following 1 Set glow plug potentiometer to maximum time fully clockwise potentiometer will click at end of travel 2 Apply power to controller All three LEDs should turn on for one second indicating normal operation 29 Woodward Manual 36598 DSS 2 Two Channel Digital Speed Switch 3 Turn on frequency generator and set to the crank disconnect frequency The green status LED should turn on continuously indicating a good speed signal from the generator 4 Apply power to the VER switch input to initiate the starting sequence The Glow Plug controller will turn on first for the pre heat duration 5 When the red LED for the autocrank channel turns on the pre heat time is over Use the glow plug channel potentiometer to adjust the pre heat time 6 Install DSS 2 on engine and confirm glow plug and autocrank operation Adjust pre heat time as required The range of pre heat times commanded is adjustable using the ACT The range can be varied with the potentiometer between zero and GLOW PLUG_TIME Glow Plug Controller Adjustment Using ACT ACT can be used to customize the range of glow plug pre heat times in the DSS 2 Refer to Chapter 5 for general information regarding installation connection and operation of ACT The Calibration Wizard is the
33. bration tool DSS 2 was designed for use on engine applications where it can perform a variety of speed related functions such as starter motor disable and engine overspeed protection DSS 2 monitors engine rom via a magnetic pickup MPU input and controls two independent relays Once engine speed exceeds the user selected speed setpoint the relay will go to the designated set condition DSS 2 can also be re configured with the ACT All purpose Calibration Tool to function as an engine autocrank controller or glow plug controller DSS 2 has two multi turn potentiometers for manual speed setpoint adjustment A computer interface is provided for additional adjustments with the All purpose Calibration Tool ACT Electrical connections consist of thirteen wires and utilize a Euro style terminal strip For most applications DSS 2 can be connected and adjusted with simple hand tools For more advanced features the calibration tool provides user friendly access Three indicator lamps permit system monitoring and diagnosis without use of additional tools As shipped from the factory DSS 2 can be manually adjusted on most applications that supply a MPU frequency of 2500 to 5000 Hz Optionally the user may attach the calibration tool ACT to gain access to a number of user adjustable features including e Frequency range 200 15 000 Hz e Normal and reverse mode operation e Automatic Manual or Latched reset e Set condition on Engine Protect
34. cccceeeeeeeseeeeeeeessaeeeseeeeeeeessaaaeeeeeees 33 Calibrate WCU EE 33 Change DSS 2 CGalbraton 33 lee eet 35 LIST Ol Ge ant 36 Download Cal File to Dap 39 Compare DGG 2CGaltobieCal 40 Change DSS 2 PaSSWOIG c1 lt s lt ccc0ssceeesseceecees innne iienaa aini 41 DSS 2 Calibration Ward 43 Montor VICI RE 44 Parameter VIEW eet eege 44 Parameter e EE 45 Reck AE EE 46 CONO UE e UE 47 Si elle DICH TE 48 glate STAN Fe OM GE 48 als E 49 Help TOPICS eee 49 PROT e WEE 49 Usar ENEE 49 CHAPTER 6 TROUBLESHOOTING ceccecescecescuceecuseecuscueeseuseeeuseususeeeuseueeseas 50 SIS SCS EE 50 OCS eege geg 50 Glossary Of Technical Temms 52 CHAPTER 7 SERVICE OPTIONS cscececeececuceececuseeeecuseueeeueeueeeueeueeeueeueesueass 53 Produc Service ge te E 53 Returning Equipment for Repair ccccsecccccseseeeeseeeeeeceeeeeeseeeeeseaseeessaeeeesaaeees 54 Replacement Parts ccccccccccccssseeeceeeeeeeseeseeecaeeseeeseeseeesseueeeeseeeeeesseeeessaesessaaeees 55 How to Contact Woochward 55 Engineering tele EE 56 MSC ATIC ll SSI SCO E 57 li Woodward Manual 36598 DSS 2 Two Channel Digital Speed Switch Regulatory Compliance European Compliance for CE Marking EMC Directive Declared to 89 336 EEC COUNCIL DIRECTIVE of 03 May 1989 on the approximation of the laws of the Member States relating to electromagnetic compatibility Electromagnetic Compatibility Testing was performed to ISO EN 14982 1998 and EN 13309 2000 stand
35. cted to battery voltage and the other side connected to the DSS 2 switch input LC nn nlna tm n 175 4 4mm 2 PLACES Ri Y Go Q Si E a a 0 D E Gi al lt E S a a D E Z lt Q N P N 8800 1001 REV 2 88 22 3mm Figure 2 DSS 2 Dimensions 8 Woodward Manual 36598 DSS 2 Two Channel Digital Speed Switch Table 1 Controller Wiring FUNCTION PIN INFORMATION Battery BAT GND MPU Speed Signal Input RPM RPM Channel 1 C 1 NC 1 NO 1 Channel 2 C 2 NC 2 NO 2 Verify Start Switch VER RST Engine Protection Switch EP ACT Connector RCV Pin 4 TXD Pin 3 GND2 Pin 1 CAUTION To prevent damage to the controller make sure that it is wired in accordance with the wiring instructions and diagrams in this manual Woodward 9 DSS 2 Two Channel Digital Speed Switch Manual 36598 Controller Pinout Use the diagram below to connect your DSS 2 controller to battery power the mag pickup loads switches and ACT NOTE All cabling for the DSS 2 controller is limited to less than 3m 9 84 Power cabling is limited to less than 10m 32 8 in total length The wiring diagram below shows specific cable types required Slow Blow Fuses EEN Power DC Salibration od atup ar li mma Realise Solenoid or other device 10 A Max Solenoid or other device OO A Man ER we Gesi Pin 1 TZD Fin 3 Adjust Twisted Pair Shielded Wir
36. d ACT may be disconnected The DSS 2 unit will continue to operate normally with ACT either connected or disconnected Woodward P N SA 5206 CAUTION An unsafe condition could occur with improper use of these software tools Only trained personnel should have access to these tools Woodward 5 DSS 2 Two Channel Digital Speed Switch Manual 36598 Chapter 2 Specifications DE Woodward P N 8800 1001 Electrical Power Input 9 30 Vdc Reverse polarity protected Electromagnetic Compatibility See Regulatory Compliance on page iil Operating Current Both Channels On 12 V 100 mA 24 V 100 mA Both Channels Off 12 V 50 mA 24 V 50 mA Resistive Load 1 to 10A Relay Contact Ratings 28 Vdc nduve loaa EECH Mechanical Operating Temperature 40 F to 185 F 40 C to 85 C 10 G s 45 Hz UV chemical resistant UL 94 V O flame retardant Encapsulated for reliability in harsh environments Calibration Manual or with PC based All purpose Calibration Tool ACT SA 5206 Weight 0 38 lbs 0 17 kg NOTE The scope of this manual does not include selection of speed sensors or other components that Woodward offers for use with the DSS 2 system Information is available on our website at www woodward com NOTE The need for sub components such as switches is application dependent Please contact Woodward for information specific to your application 6 Woodward Manual 36598 DSS
37. data into the DSS 2 or the ACT Entering values outside of safe operating range can result in serious physical injury and or damage to the equipment or application Woodward 13 DSS 2 Two Channel Digital Speed Switch Manual 36598 Speed Switch Configuration As shipped from the factory DSS 2 is configured as follows e Two channel speed switch e Normal operation e Automatic reset at 80 of setspeed e Range of pot adjustable set speed 2500 to 5000 Hz e Go to set condition on EP switch input e Set speed reduced to 70 on VER switch input The speed setpoints can be calibrated manually by adjusting the two potentiometers on the front of the DSS 2 controller A typical speed switch installation is shown below In this example Channel 1 is configured as a crank disable switch that disconnects power to the starter motor when engine speed rises above the set speed Channel 2 is configured as an overspeed shutdown switch that will interrupt power to the ignition coil when an overspeed threshold is exceeded Slow Blow Fuse em Z Cy Nee gt a Slow Blow Fuse Slow Blow Fuse a doamp Oem En Mag Pickup SE Crank Disable Ignition Kill Relay Relay R Han AS EA D O bi el hace e eo bot wi bia Gan D el d all R Eae U S Lu Rat h oll VER d Lu t G d Twisted Pair Shielded Wire shield grounded at controller only DSS2 Controller
38. e 2 Select default values or current values as a starting Te seca calibrated The Reset option a all calibration parameters It is recommended that the update option be used or Calibrate gt Change Calibration point in the calibration When to change indvidual parameters adjusting a DSS 2 that for the most part has the Ge desiredc alibration itis best E Start with curent values Oniy the caibration data thal changed wil be updated to use current values WIES The Wizard will be dee with the default values read from the vi calibration file All calibration values will be reset i Cancel DSS 2 Calibration Wizard 3 Enter the number of teeth on Configure Engine Speed Input the flywheel If you wish to work in Hz enter a value of How many teeth does the Flywheel have 60 If you wish to work in rom enter the correct number of flywheel teeth 4 Information in the following sections will detail how ACT can be used to configure both channels and the Engine Protection EP input lt Back Cancel CAUTION The DSS 2 is a user configurable engine control device 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 DSS 2 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
39. e Magnetic Pickup i OR shield grounded at controller only fies gt lt gt lt lt E Engine Protect DSS 7 Controller Channel 1 Adjust Manual Reset Ha Figure 3 DSS 2 Wiring Diagram 10 Woodward Manual 36598 DSS 2 Two Channel Digital Speed Switch Speed Sensor Installation Installed opposite an engine driven gear such as the flywheel the mag pickup MPU transmits a signal each time the magnetic flux path across the pole is interrupted by a gear tooth The frequency of the AC signal generated by the MPU is proportional to the engine speed The mounting of the sensor unit must be rigid excessive vibration can cause erroneous signals and unreliable performance MPU output voltage is affected by tooth speed and gap size between the sensor and the gear tooth The higher the tooth speed the higher the output voltage Conversely the larger the sensor gap the lower the output voltage In general gap of 0 015 to 0 018 0 38 to 046mm is adequate for most engines and operating speeds If the gap cannot be measured it may be adequate to do the following 1 Align a gear tooth in the center of the hole 2 Install the MPU until the tip touches the tooth This assumes that the hole is tapped to the full depth and no burrs exist which preclude moving the sensor all the way up to the tooth Unscrew the MPU approximately one quarter to one half turn While
40. e 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 received 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 Gi 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 current faults The display will also show historical fault codes that have been previously logged but do not currently exist Historical fault codes are helpful when tracking down intermittent faults E Diagnostic View To Display Faults in Real Time 1 Choose Monitor gt Display Faults from the main menu The application will launch the Fault view Historical Faults The application will update the Deien e 7 display every time the controller Clear Historical Faults oa D E Ze EH D sends the fault_flags status This happens several times a second 2 Click on the Pause button to stop the automatic update of this 46 Woodward Manual 36598 DSS 2 Two Channel Digital Speed Switch screen The text on the button will chan
41. e 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 conductors on a printed circuit board with your hands or with conductive devices IMPORTANT DEFINITIONS A WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury A 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 Revisions Text changes are indicated by a black line alongside the text 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 Woodward 2005 All Rights Reserved Manual 36598 DSS 2 Two Channel Digital Speed Switch Contents a l REGULATORY COMPLIANCE ccsccecnececnecnenecnsceeneceseecueceeneceeneceenecaseesuenenaens lll ELECTROSTATIC DISCHARGE AWARENESG sscccsenececnenececneneceeneneceesenenenas IV CHAPTER 1 GENE
42. ermits the system to ignore small glitches in measured engine speed Go to Set Condition on Engine Protection Switch If the Engine Protection box is checked the speed switch will go to the set condition any time the Engine Protection Switch input is set to a high voltage regardless of the speed Go to Set Condition when Start Verify Switch is off To use the VER input as a Start Stop switch check the Verify Switch box Any time the VER input is low the speed switch will go to the set condition regardless of the speed As long as the speed is below the set speed the speed switch will return to the reset condition when the VER input is connected to high voltage This feature is useful when using the speed switch for overspeed shutdown as well as start stop When this feature is enabled on either channel the normal verify function will be disabled Go to Set Condition on Loss of Speed If the Loss of Speed Set box is checked the speed switch will go to the set condition upon loss of the speed signal This can be used to assure an engine shutdown in the event that the MPU signal is lost Sequence with other channel If the Sequence box is checked the speed switch will not go to a set condition based on speed until after the other channel has gone to a set condition To generate a fault code when a set condition seen When auto reset is used there is not an indication to the operator that a speed switch has gone to the set conditio
43. eset percentage 80 of set speed at which reset will SET DELAY 2 Time above set speed before set ieee will occur SET SPEED 2 MIN Minimum set speed frequency 2500 Hz 7 from Channel 2 potentiometer SET SPEED 2 MAX Maximum set speed frequency 5000 Hz from Channel 2 potentiometer Speed Input Configuration PULSES PER_REV PULSES PER UPDATE No of pulses until next engine speed update No of pulses per engine revolution if set to 60 rom Hz Woodward 37 DSS 2 Two Channel Digital Speed Switch Manual 36598 Parameter List Cont d CATEGORY PARAMETER DESCRIPTION Ge EP ENABLE RPM Minimum rpm to enable engine T protection switch Minimum time above EP RUN TIME EP_ENABLE_RPM to enable 0 sec engine protection switch Minimum engine protection switch Protection Switches Minimum time without speed signal on startup to go to set condition if Ee SS Loss of Speed Signal set mode is SES enabled CHNL_X_COFIG 4 1 Percentage of normal set speed to TEST _VERIFY_K go to set condition when Verify 0 7 Switch is activated 1 Disable autocrank if engine AJTOGRANK ONS protection fault exists e AUTOCRANK_CRANK__ Maximum engine cranking time 10 sec TIME before resting AUTOCRANK_MAX__ Maximum number of crank TRIES attempts Time between onset of cranking AUTOCRANK_NS_TIME_ and a fault if no engine speed is 1 sec Autocrank observed Glow Plug Calibration oo Rest time between crank attempts Engine rom ab
44. essfully Lai WI CWoodward 4cT 7_3 My Data ACT 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 DSS 2 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 DSS 2 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 Select a Calibration file and its comments are displayed Kli Look in Act 7 3 S DEmos00 000 E pemonss2 000 E aPx41c07 000 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 Calibration Comments 1 Choose File gt View Cal File Comments ACT will display a list of files on the left side of the screen with file comments on the right E aPx41m03 000 E aPx41M04 000 E aPx41m05 000 E aPx41P05 000 E aPx51501 000 lt E DEMO1000 000 E DEMO3000 000 E DEMO4000 000 3 DEmo4500 000 E pEmos000 000 E Gator_CO6 ACT Lait 000 E 5D0113D AcT e 55511M03 000
45. ete the download operation 1 When a password mismatch is detected the ACT displays a message Cal File password differs from that of the DSS 2 unit Download the Cal File password to the DSS 2 unit 2 If you answer Yes to this message see note below the calibration file will be downloaded and the password in the DSS 2 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 Gi Before answering Yes to the message make sure you know the password in the calibration file lf you do not know the password you will not be able to access the password protected features under the Calibrate menu Please see Change DSS 2 Password command for more information on password protection Compare DSS 2 Cal to File Cal This command lets you check the differences in calibration sets between a saved file and the DSS 2 unit The feature is useful for example to ensure that the saved file matches the calibration in the DSS 2 unit To Compare DSS 2 Cal to File Cal Choose a Calibration file to compare Look in CQ ACT 7_3 M 5 c E jacscsta7 o00 E aPx41co7 o00 Srrwoenm mn Srrwopesz mt 1 Choose File gt Compare DSS 2 Cal to Bjasscstas o00 Slapvaiu 000 m oemorooo 000 E Gator_co6 AcT File Cal This screen allows you to select Sapxo1mo1 000 Sat 200 E DEmos000
46. etween crank attempts Maximum number of crank attempts Specifies the maximum number of attempts to start the engine LS Geo after which the autocrank sequence will be terminated Maximum Crank Disable Speed rpm Specifies the maximum crank disable rom selectable with the channel potentiometer Minimum Crank Disable Speed rpm Specifies the minimum crank disable rom selectable with the channel potentiometer To disable autocrank when an engine protection fault exists Checking the box labeled Disable crank on Engine Protect will terminate the autocrank process if a high voltage exists on the EP switch input Glow Plug Controller Configuration As shipped from the factory both DSS 2 channels are configured as speed switches The ACT is required to enable glow plug controller operation The other channel must be configured for Autocrank operation Once enabled the Glow Plug Preheat time can be manually adjusted using the potentiometer The ACT can be used to adjust maximum engine pre heat time The glow plug sequence is as follows 1 The autocrank glow plug sequence is initiated by applying battery power to the VER switch input If power is removed from the VER switch input at any time the sequence will be terminated 2 The channel configured as a glow plug controller will turn on for the pre heat time The LED for the glow plug channel will be illuminated The autocrank channel will remain off through the dura
47. f custom features to the DSS 2 Refer to Chapter 5 for general information regarding installation connection and operation of ACT The Calibration Wizard is the preferred approach to ACT calibration but similar results can be obtained using the Calibrate Change DSS 2 Calibration Menu item To launch the Calibration Wizard 1 Select Calibrate then Calibration Wizard 2 Select default values or current values as a starting point in the calibration 3 Enter the number of teeth on the flywheel If you wish to work in Hz enter a value of 60 If you wish to work in rom enter the correct number of flywheel teeth 4 The following information applies to both Channel 1 and Channel 2 Woodward 15 DSS 2 Two Channel Digital Speed Switch Manual 36598 Normal Operation vs Reverse Operation In the first Wizard window left click on the down arrow in the selection box and select normal or reverse operation Click on Next to move on to the next selection DSS 2 Calibration Wizard Channel Configuration Channel 1 Channel Configuration Normal Speed Switch Mode v Normal Speed Switch Mode Reverse Speed Switch Mode Autocrank Controller Glow Plug Controller lt Back Cancel Reset Mode Auto Manual Latch Click on the down arrow in the selection box and select the desired reset mode Auto Reset The speed switch will automatically return to the Reset state when speed falls below a percentage of the setspeed The pe
48. f 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 Number 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
49. ge to Start and clicking it again will re start the automatic updating NOTE Gi If any other screen requests data from the controller while this screen is updating this screen 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 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 E Parameter List toggle the selected Cal File Name LSSOIMO1 O00 GE SS View List Information parameter on the ame e Parameter View Ge weesen TZ a_c_flash_cntr screen 7 3 Click on the x box in the title bar or press lt Esc gt to SEN close the screen ne Open 1 save Edits are not F5 PREVIOUS F6 NEXT F9 ADD REMOVE ON VIEW ESC CANCEL EDIT CLOSE saved between application launches 4 Ifthe Parameter View 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 to T
50. gine rest time between crank attempts e Maximum number of crank attempts before giving up e Range of pot adjustable crank disconnect speed default value 2500 to 5000 Hz e Disable autocrank on EP switch input lf either channel is configured for autocrank the normal Verify function is disabled The autocrank sequence is as follows 1 The autocrank sequence is initiated by applying battery power to the VER switch input If power is removed from the VER switch input at any time the autocrank process will be terminated 2 If one of the channels is configured as a glow plug controller it will turn on for the pre heat time The autocrank channel will remain off through the duration of the glow plug pre heat cycle 3 The autocrank channel and the red LED will turn on to initiate cranking If an engine speed signal is not seen within AUTOCRANK_NS_TIME a fault will be generated and the autocrank sequence terminated 4 The autocrank channel will remain on for AUTOCRANK CRANK TIME seconds or until engine speed rises above the crank disconnect speed whichever comes first 5 If engine speed rises above the crank disconnect speed the autocrank process is complete 6 If the autocrank channel remains on for AUTOCRANK_CRANK_TIME seconds the channel will turn off and enter the rest phase for AUTOCRANK_REST_TIME seconds during which time the red channel LED will flash rapidly 7 After AUTOCRANK_ REST_TIME seconds the crank process will be
51. ile 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 DSS 2 Cal to Text This command allows you to create a text file of DSS 2 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 DSS 2 Calibration to Text 1 Choose File gt Convert DSS 2 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 32 Woodward Manual 36598 DSS 2 Two Channel Digital Speed Switch 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 display the file using the default text viewer Convert C
52. ine Protection EP input to the DSS 2 Refer to Chapter 5 for general information regarding installation connection and operation of ACT The Calibration Wizard is the preferred approach to ACT calibration but similar results can be obtained using the Calibrate Change DSS 2 Calibration Menu item To launch the Calibration Wizard Select Calibrate then Calibration Wizard 2 Select default values or current values as a Starting point in the calibration 3 Enter the number of teeth on the flywheel If you wish to work in Hz enter a value of 60 If you wish to work in rom enter the correct number of flywheel teeth 4 Follow the steps covered in previous sections to configure the two speed switch channels DSS 2 Calibration Wizard Engine Protection Setup Enable RPM 0 0 Run Time sec 0 0 Debounce Time msec 50 Loss of Speed Signal time sec 5 0 lt Back Cancel To ignore EP input before starting Some engine protection inputs such as oil pressure switches indicate a failure when the engine is not running To prevent latching of unintended faults set Enable RPM to a non zero value that indicates normal engine operation 24 Woodward Manual 36598 DSS 2 Two Channel Digital Speed Switch To Ignore EP input for a brief period after starting Set Run Time sec to a non zero value To ignore intermittent switch contact closures To provide some basic switch contact debounce set
53. ion EP switch on e Set condition on loss of speed signal e Set condition on Start Switch VER off e Autocrank Configure crank disconnect speed range crank time rest time and number of crank attempts e Glow plug preheat Intended Usage The DSS 2 is intended as a sub system for integration into construction commercial and industrial engine systems by original equipment manufacturers and industrial plants It is not intended for consumer or on highway vehicles or for use by the general consumer public Typical applications include generator sets compressors construction machinery and farm vehicles Woodward 1 DSS 2 Two Channel Digital Speed Switch Manual 36598 Slow Blow Fuse a Start Switch Slow Blow Fuse Slow Blow Fuse 10 amp 0 amp Crank Disable Relay Ignition Kill Relay Twisted Pair Shielded Wire shield grounded at controller only DSS2 Controller Figure 1 DSS 2 Engine Control System How Speed Switches Work The purpose of a speed switch is to monitor the speed of a rotating device such as an internal combustion engine and close or open a set of switch contacts when speed exceeds a threshold Speed switches are most often used to disengage starter motors when the engine starts and to shut down the engine should an overspeed occur With the addition of some logic soeed switches may be applied to a number of applications Electrical loads controlled with a speed s
54. isting 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 Manuals This command accesses the User Manual which includes comprehensive information on the DSS 2 controller wiring diagrams ACT software menus and calibration parameters The manual may be viewed online or printed for future reference Woodward 49 DSS 2 Two Channel Digital Speed Switch Manual 36598 Chapter 6 Troubleshooting General Checklist Please follow the checklist below to troubleshoot your DSS 2 controller We recommend using a digital multimeter capable of measuring frequency and duty cycle such as a Fluke 83 or Fluke 87 1 Check battery voltage for stability and correct value The LED will turn on for one second when the DSS 2 is first powered up 2 Confirm that magnetic pickup output voltage is at least 2 Vim using the AC volt settings on voltmeter The LED will illuminate when it senses an engine speed 3 Confirm that the channel LEDs transition at the appropriate frequencies 4 With the loads disconnected from DSS 2 use an ohmmeter to confirm that relays are working as expected With no power to the relay there should be continuity between the C and NC contacts and no continuity between C and NO contacts
55. k The DSS 2 speed switch channels can be easily configured to provide an autocrank feature using the ACT In this mode applying battery voltage to the VER input will initiate the starting sequence When this happens the relay will be energized until either the engine starts or a maximum crank time is exceeded If the latter occurs the logic will wait for a rest period before attempting to crank again Crank Time Rest Time and Maximum number of crank attempts are user selectable using the ACT The rpm at which the DSS 2 assumes the engine has started referred to as the crank disable speed is adjustable using the multi turn potentiometer for that channel Glow Plug Preheat When one channel of the DSS 2 has been configured for autocrank the user may configure the other channel as a glow plug controller In this mode the DSS 2 will energize the glow plug relay for a fixed period of time before engine cranking begins The relay will remain on until the end of the crank period or until the engine starts whichever comes first The glow plug relay will remain on during the rest period provided that the glow plug preheat time is longer than the rest time if not the glow plug relay will be turned off until the appropriate preheat delay prior to the next crank attempt The maximum glow plug preheat time is user selectable using the ACT The actual preheat time is adjustable between zero and the maximum using the multi turn potentiometer for that
56. low Table 1 Calibration Categories and Features CALIBRATION CATEGORY FEATURES AVAILABLE Operating Mode Normal Reverse Autocrank Glow Plug Channel 1 Calibration Reset Mode Auto Switch Latch Speed Range Set Reset Delays Operating Mode Normal Reverse Autocrank Glow Plug Channel 2 Calibration Reset Mode Auto Switch Latch Speed Range Set Reset Delays Speed Input Calibration Number of pulses on flywheel Engine Protection Switch Enable rom delay Crank Time Autocrank Glow Plug Calibration Rest Time Maximum Crank Attempts All Parameters Contains list of all calibration parameters Woodward 35 DSS 2 Two Channel Digital Speed Switch Manual 36598 List of Parameters The parameter list provides information regarding each of the parameters that can be adjusted when a computer is connected to the controller via the COM port and the ACT software The COM port and ACT are intended only for configuration and periodic service Do not leave a computer and or COM cable connected to the COM port CATEGORY PARAMETER DESCRIPTION Ge At Configuration bits Channel 1 Bit 7 1 Overspeed Fault Enable Bit 5 1 Sequence bit Ch 1 after Chi CHNL_1_CONFIG Bit 4 1 Go to set on Loss of 000000001B Speed Signal Bit 3 1 Go to set on Verify Sw Off Bit 0 1 Go to set on EP switch active 0 speed switch standard relay logic 1 speed switch reverse relay CHNL 1 OP MODE logic 2 au
57. ly File name Cancel Calibration File Comments 1 DSS 2 Calibration for 8 engine 2 Channel 1 Crank Disconnect at 700 rpm 3 Channel 2 Engine Overspeed Protectionn at 2000 rpm 5 Engine Protection enabled 7 Greg Pence 7 15 05 2 Choose a file and click OK The following screen will show the progress Processing Calibration Values OVERSPEED_RPM 3 The following screen is shown when the operation is complete ACT i Ki A The calibration file was downloaded successfully NOTE During the Download Cal File to DSS 2 operation the user may encounter a situation where the Cal File password is different from that of the DSS 2 unit If this happens please refer to the steps below to complete the download operation Woodward 39 DSS 2 Two Channel Digital Speed Switch Manual 36598 To Download a Cal File to DSS 2 with a Password Different from that of the DSS 2 Unit Whenever the DSS 2 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 DSS 2 operation if the password stored in the calibration file matches the password in the unit ACT will readily download the calibration to the DSS 2 unit However if the password stored in the calibration file does not match the password in the DSS 2 unit ACT will alert you of a password mismatch Please follow the steps below to compl
58. mand 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 DSS 2 unit By default the DSS 2 unit is not password protected To Change DSS 2 Password Please enter the controller password 1 Choose Calibrate gt Change DSS 2 Password You willbe prompted status _ Change Cancei for the current password Enter password and click OK Woodward 41 DSS 2 Two Channel Digital Speed Switch Manual 36598 2 The application will S query the controller to verify that the entered password matches the Bate Gre Ine COMME Passion current password If the fearon Be Cea password matches the Change button is enabled SE Change Cancel Password Valid Click Change to change controller password 3 Click Change and the application will prompt for the new password Password Management E X Enter new Password coed 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 ZEISS x 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
59. n and generated data files should be considered as Bes reference only engine_rpm rpm fi 576 142 engine_speed rpm f 525 000 The X axis time scale 25 seconds in the example screen may be shorter than configured 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 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 1 On the Parameter Plot screen click on Configure The application will show the following screen with the current values Woodward 45 DSS 2 Two Channel Digital Speed Switch Manual 36598 x Plat 2 Jengine_speed MM Avis Max Asis Max fi 900 Asie Mm Asis Min f 400 Awe Tine Scale fz20 sec Humber Vertical Divisions 11 Asie Sample Aate ES m ec Number Horizontal Divisions Di 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 Tim
60. n and then returned to the reset condition Checking the Overspeed Fault Enable box will generate a fault code if the speed switch ever goes to the set condition The green status lamp will flash a fault code indicating the overspeed fault Delay on Reset Condition When the speed switch is configured for automatic reset Reset Delay specifies how long in msec that actual soeed must fall below the reset speed before going to the reset condition This permits the system to ignore small glitches in measured engine speed Reset Speed Set Speed Reset Percentage This option is not displayed if manual reset or latched reset is selected To Adjust Reset Speed When the speed switch is configured for automatic reset the user can select the speed below which the speed switch will return from the set Woodward 17 DSS 2 Two Channel Digital Speed Switch Manual 36598 condition to the reset condition The reset speed is expressed as a percentage of the set speed so that adjustments to the set speed with the set speed potentiometer will also affect the reset soeed Reset Speed Set Speed Reset Percentage Autocrank Configuration As shipped from the factory both DSS 2 channels are configured as speed switches The ACT is required to enable Autocrank operation Once enabled the Crank Disconnect rom can be manually adjusted using the potentiometer Other features which can be adjusted using the ACT include e Maximum engine cranking time e En
61. nly it is not intended for a cable connection during operation 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 DSS 2 must be powered up in order for ACT to operate CAUTION Gi The serial COM port and ACT software are intended only for configuration and periodic service Do not leave a computer and or serial COM cable connected to the serial COM port 26 Woodward Manual 36598 DSS 2 Two Channel Digital Speed Switch ACT HARNESS Gnd CONNECTOR MOLEX 39 01 2040 Vbatt TERMINALS MOLEX 39 00 0039 9 30 VDC COMPUTER Figure 7 ACT System Set Up W woopwarp 2 CHANNEL DIGITAL SPEED SWITCH P N e 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
62. o Made display the following screen C Con C EPS 1000 Cancel C Com C APECS 500 2 Choose a port and click OK gt Canton ares aom 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 f APECS 4000 f APECS 4500 f APECS 5000 e 55 2 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 48 Woodward Manual 36598 DSS 2 Two Channel Digital Speed Switch 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 Manuals 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 topic through an alphabetical l
63. ove which CRANK_DISABLE autocrank will be terminated and 700 rpm normal engine rom assumed Maximum glow plug preheat time before enabling crank The actual GLOW PLUG_TIME glow plug preheat time can be 10 sec adjusted downward with the potentiometer 38 Woodward Manual 36598 Download Cal File to DSS 2 DSS 2 Two Channel Digital Speed Switch The Download Cal File to DSS 2 command allows you to download the entire calibration set from a file to the DSS 2 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 DSS 2 units for a particular application The downloaded file may have been previously configured and calibrated for satisfactory engine performance with another DSS 2 unit To Download a Cal File to DSS 2 1 Choose Calibrate gt Download Cal File to DSS 2 The following screen allows you to select a Cal file to Choose a Calibration file to download Look in ACT 7 3 e e E aPx41c07 000 E APx41m03 000 E aPx41m04 000 E APX41M05 000 E aPx41P05 000 E aPx51501 000 E DEMoso0 000 E DEMo1000 000 E DEMo3000 000 3 DEMo4000 000 E DEMo4s00 000 E DEMoso00 000 E DEMopss2 000 E Gator_CO6 ACT d LS501M01 000 E 5D0113D ACcT e 55511M03 000 download E My Data ACT Files of type Cal Files 000 4CT e Dpen as read on
64. preferred approach to ACT calibration but similar results can be obtained using the Calibrate Change DSS 2 Calibration Menu item To launch the Calibration Wizard 1 Select Calibrate then Calibration Wizard 2 Select default values or current values as a starting point in the calibration 3 Enter the number of teeth on the flywheel If you wish to work in Hz enter a value of 60 If you wish to work in rom enter the correct number of flywheel teeth 4 The following information applies to both Channel 1 and Channel 2 Enabling Glow Plug Control DSS 2 Calibration Wizard Channel Configuration Channel 1 Channel Configuration V lker v nindow left click H H Autocrank Controller window left click on Glow Plug Controle the down arrow in the selection box and select Glow Plug Controller Click on Next to move on to the next selection lt Back Cancel Woodward 23 DSS 2 Two Channel Digital Speed Switch Pre Heat Time DSS 2 Calibration Wizard Channel Configuration Channel 1 Channel Configuration Glow Plug preheat time sec 10 0 i Cancel Manual 36598 Range of Adjustable Pre heat Time This parameter adjusts the maximum value for Glow Plug pre heat time The multi turn potentiometer for the channel assigned to glow plug control can be used to adjust the pre heat time between zero and this paramer Engine Protection Switch Configuration ACT can be used to configure the Eng
65. rcentage is selected in the next window Manual Reset The speed switch will return to the Reset state when the speed falls below the setspeed AND the RST switch input is connected to battery voltage Latched Reset The speed switch will remain in the Set state until the DSS 2 module is powered down then powered back up DSS 2 Calibration Wizard Channel Configuration Channel 1 Channel Configuration Reset Option E EE TE Automatic Reset on of Set Speed Reset with Manual Reset switch Latched reset lt Back Cancel 16 Woodward Manual 36598 DSS 2 Two Channel Digital Speed Switch Speed Switch Options DSS 2 Calibration Wizard Potentiometer Control Range Channel Configuration Channet 1 Set Speed Min and Set Channel Configuration Normal Speed Switch Mode v Reset Option Automatic Reset on of Set Speed Speed Max specify the Set Speed Min pm emt range of engine speeds Set Speed Max emt SR frequencies controllable Set Delay msec 1000msec 1sec fo Engine Protection with the set speed Verity Switch potentiometer Values of Loss of Speed Set 10 8000 are acceptable Sequence The narrower the range ees the finer the resolution on Reset Delay msec 1000msec 1sec 0 D Reset Percentage 0 79999 adj u st m e nt a Delay on Set Condition Set Delay specifies how long in msec that actual Cancel speed must exceed the set speed before going to the set condition This p
66. referred approach to ACT calibration but similar results can be obtained using the Calibrate Change DSS 2 Calibration Menu item To launch the Calibration Wizard 1 Select Calibrate then Calibration Wizard 2 Select default values or current values as a starting point in the calibration 3 Enter the number of teeth on the flywheel If you wish to work in Hz enter a value of 60 If you wish to work in rom enter the correct number of flywheel teeth 4 The following information applies to both Channel 1 and Channel 2 Enabling Autocrank DSS 2 Calibration Wizard Channel Configuration Channel 1 Channel Configuration In the first Wizard Reverse Speed Svtch Mode window left click on the down arrow in the selection box and select Autocrank Controller Click on Next to move on to the next selection lt Back Cancel 20 Woodward Manual 36598 DSS 2 Two Channel Digital Speed Switch Autocrank Options Engine Crank Time sec This option permits DSS 2 Calibration Wizard adjustment of the maximum Channel Configuration Channel Eer crank duration If crank time exceeds this time the engine will enter a rest SE period Fleet Time eee Maximum number of crank attempts Channel Configuration a Maximum no start time sec Rest Ti m e sec Maximum Crank Disable Speed pm This option specifies the Minimum Crank Disable Speed rpm rest or cooling period Disable crank on Engine Protect b
67. s attach a tag with the following information e name and location where the control is installed e name and phone number of contact person e complete Woodward part number s and serial number s e description of the problem e 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 e protective caps on any connectors e antistatic protective bags on all electronic modules e packing materials that will not damage the surface of the unit e at least 100 mm 4 inches of tightly packed industry approved packing material a packing carton with double walls e a strong tape around the outside of the carton for increased strength 54 Woodward Manual 36598 DSS 2 Two Channel Digital Speed Switch Return Authorization Number When returning equipment to Woodward please telephone and ask for the Customer Service 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 o
68. sdeatictoxteatatensies 17 Autocrank Configuration BEE 18 Manual Calibration ccccccccccccccesseeeeeeceeeeeeeeseeeseeeeeseeeeeeeesseeaseeesesaegeeeeeesas 19 Autocrank Calibration Using ACTA 20 Enabling free EH 20 Tee ge Le e EE 21 Glow Plug Controller Configuration ccccccccsseeeeeeeseeeseeeeeeeeeeeeeeseeeeeeeesaaaeeeess 21 Manual C leen sissien iei T EEEO 22 Glow Plug Controller Adjustment Using ACTA 23 Enabling Glow Plug Control 23 Pre Heat Hu TE 24 Engine Protection Switch Configuration cccccccccccccceeseseeseeeeeeeeeeeseeeeeeeeeeeseaas 24 Completing Wizard Contguraton 25 Woodward DSS 2 Two Channel Digital Speed Switch Manual 36598 Contents cont d CHAPTER 5 ACT OPERATION ene Neger deeeiesgegen ees EAR 26 AGT AN Sl AMO re e EEN 26 AGT Kit GOMES stunge Eege 26 SCUD REGUIFE EC 26 Hardware Get up 26 Software GeilUlnp cccccccssessceccceeeeeeeeseeceeeeeeeeeeeeeeeeeeeeseeeaseeeeeeeesssaaseeeeeeees 27 BASIC AGT Operati n E 28 RUNNING THE AGT e serani anioien aE E AAEN aeae 28 Progress Display Sre EE 28 Moving Around the Gotftware 29 ACT Menus amp e EE 29 ACT Menu Structure ccccccccceccecceececcecceeceecaecceeceecueceecueceecueceecueeueeneeaeens 29 SICH EE 30 Stee 30 Save DSS 2 Calio File aa eee ee ee eee raa 30 View Cal File Comments 31 VEN TEO TE 32 Convert Commande 32 Convert DSG 2CGaliolfevt 32 Convert Cal Eiletofevt 33 Convert Cal File to Strategy cccccccesces
69. second indicating normal operation 3 Turn on frequency generator and set to desired crank disconnect frequency The green status LED should turn on continuously indicating a good speed signal from the generator Woodward 19 DSS 2 Two Channel Digital Speed Switch Manual 36598 4 Apply power to the VER switch input to initiate the starting sequence If one channel is configured as a Glow Plug controller it will turn on first for the pre heat duration 5 When the red LED for the autocrank channel turns on begin turning the potentiometer counterclockwise until the LED turns off If the crank timer times out before reaching the crank disconnect speed the LED will begin flashing rapidly indicating the rest period between crank attempts Resume adjustment when the next crank cycle begins or cycle power to the VER switch to re initiate the crank sequence 6 Install DSS 2 on engine and confirm MPU input with engine running Confirm autocrank operation The range of setspeeds commanded 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 The wider the range the coarser the resolution Autocrank Calibration Using ACT ACT can be used to customize the Autocrank feature in DSS 2 Refer to Chapter 5 for general information regarding installation connection and operation of ACT The Calibration Wizard is the p
70. setpoint and CHNL_1_CONFIG 7 1 Engine rom has exceeded Channel 2 Channel 2 Set Condition speed setpoint and Overspeed CHNL_2CONFIG 7 1 Engine Protection Set Condition Engine Protection switch activated Disappearance of speed signal No speed signal within LOSS_TIME of power up Loss of Speed Set Condition OR Signal No speed signal within AUTOCRANK_NS_TIME of autocrank Channel 1 Overspeed There have been AUTOCRANK_MAX__ Overcrank No autocrank TRIES attempts to start engine and engine has not started Parameter PULSES PER REV must have a non zero value Enter the DSS 2 number of teeth per engine rev if you Uncalibrated NO ORGTANON wish to work in units of RPM or enter a value of 60 if you wish to work in units of Hz Defaults to Channel 1 Set Pot minimum Consult factory out of range speed Defaults to Channel 2 Set Pot minimum Consult factory out of range speed Controller unit Yes Consult factory failed Woodward 51 DSS 2 Two Channel Digital Speed Switch Manual 36598 Glossary of Technical Terms ACT All purpose Calibration Tool Software PC software program for configuring and calibrating the DSS 2 controller Actuator Device that converts an electrical signal from the DSS 2 controller to an output shaft position Cal File File containing DSS 2 calibration data Cal Tool Version The version of calibration tool software in use Calibration Process of configuring and
71. st and as an indication of normal operation Green LED The green LED is an engine status indicator and functions as follows OFF No engine speed ON Engine speed sensed Flashing Fault present Red LEDs The red LEDs are each assigned to a speed switch channel e When achannel is configured as a speed switch its LED will be illuminated when the channel relay is in the Set condition e When a channel is configured as a glow plug controller its LED will be illuminated when the relay is energized glow plug ON e When achannel is configured as an autocrank controller its LED will be illuminated when the relay is energized The LED will flash rapidly during the starter rest period relay de energizedq 4 Woodward Manual 36598 DSS 2 Two Channel Digital Speed Switch Speed Sensor DSS 2 monitors engine speed continuously using a magnetic pickup MPU which detects the passing of teeth on an engine driven gear ed flywheel The frequency of the voltage generated by the MPU is proportional to engine rpm A variety of MPU sensors are available from Woodward 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 DSS 2 controller The tool can be run on any IBM compatible computer that meets the requirements listed ACT Installation in Chapter 5 Once the DSS 2 controller has been programme
72. tatic electric charges as much as synthetics 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 Do not remove the printed circuit board PCB from the control cabinet unless absolutely necessary If you must remove the PCB from the control cabinet follow these precautions e Do not touch any part of the PCB except the edges H 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 A 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 Manual 36598 DSS 2 Two Channel Digital Speed Switch Chapter 1 General Information Introduction DSS 2 Digital Soeed Switch 2 Channel is a two channel electronic speed switch that combines the convenience of manual adjustments with the flexibility of a computer based cali
73. tion of the glow plug pre heat cycle 3 Following the glow plug preheat the autocrank channel and the red LED will turn on to initiate cranking The glow plugs will remain on during cranking and will turn off once the engine starts 4 During the autocrank rest period the glow plugs will remain on if the pre heat time is greater than AUTOCRANK_REST_TIME If the pre heat time is less the glow plugs will be turned off until pre heat time before the next crank attempt 5 If engine speed rises above the crank disconnect speed the autocrank process is complete and the glow plugs will be turned off Woodward 21 DSS 2 Two Channel Digital Speed Switch Manual 36598 A typical glow plug installation is shown below In this installation Channel 1 is configured as an autocrank controller that will energize the starter motor when the Start Switch is turned on and after the glow plug pre heat sequence is complete Channel 2 is configured as a glow plug controller that will energize the glow plug relay as soon as the start switch is turned on Additionally an oil pressure switch is connected to the engine protection EP input Slow Blow Fuse Clow Plug Retay Slow Plugs i i NM AN Show Blow Fuse Slow Blow Fuse CH 10 amp 10 amp Diesel Engine Es l VE Twisted Pair Shielded Wire shield grownded at controller only D552 Controler Figure 6 Typical Glow Plug Installation Manual Calibration Cali
74. tocrank using Verify Sw Channel 1 3 glow plug mode using Verify Calibration Sw 0 1 auto reset at RESET PCNT_1 of Channel 1 CHNL 1 RESET set speed 2 reset with external RST switch 3 latched reset RESET DELAY 1 When in auto reset time below 7 7 reset speed before reset occurs RESET PCNT_1 When in auto reset percentage of set speed at which reset will occur SET DELAY 1 Time above set speed before set will occur SET SPEED 1 MIN Minimum set speed irequency from 2500 Hz Channel 1 potentiometer SET SPEED 1 MAX Maximum set speed trequency from 5000 Hz Channel 1 potentiometer 36 Woodward Manual 36598 DSS 2 Two Channel Digital Speed Switch Parameter List Cont d CATEGORY PARAMETER DESCRIPTION Sa 000000001B CHNL_2 CONFIG CHNL_2 OP_MODE CHNL_2 RESET Channel 2 Calibration Configuration bits Channel 2 Bit 7 1 Overspeed Fault Enable Bit 5 1 Sequence bit Ch 1 after Ch 1 Bit 4 1 Go to set on Loss of Speed Signal Bit 3 1 Go to set on Verify Sw Off Bit 0 1 Go to set on EP switch active 0 speed switch standard relay logic 1 speed switch reverse relay logic 2 autocrank using Verify Sw 3 glow plug mode using Verify Sw 0 1 auto reset at RESET PCNT_1 of Channel 1 set speed 2 reset with external RST switch latched reset RESET DELAY 2 When in auto reset time below Gansde reset speed before reset occurs RESET PCNT 2 When in auto r
75. witch include Starter relays ignition system power indicator lamps glow plug relays solenoids and electro hydraulic valves Set vs Reset Speed switches make frequent use of the terms Set and Reset The Reset condition or state is that which exists when the unit is first powered up and when engine speed is below the speed threshold Once speed rises above the threshold set speed the speed switch output relay transitions to the Set condition In some cases depending on configuration the speed switch can return to the Reset condition when engine speed drops below a lower threshold reset point or when a manual reset switch is actuated The speed switch may also be configured to latch a Set condition until battery power is cycled Normal vs Reverse Relay Logic A normally configured speed switch channel has the relay de energized in the Reset condition and energized in the Set condition It is possible to configure each channel in Reverse mode such that the relay is energized in the Reset condition and de energized in the Set condition This is helpful in applications such as engine crank disable where a loss of power to the DSS 2 should produce the same response as o Woodward Manual 36598 DSS 2 Two Channel Digital Speed Switch exceeding the set engine speed Configuring a channel in normal mode for a crank disable feature could cause overcranking if power were interrupted to the DSS 2 Autocran
76. ype in a file name that reflects the purpose Save in ACT 7 3 of the saved configuration and click Save The view configuration dialog will now display the selected 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 Flenane My Dery Dad saved parameters Save as type ACT View Setup Files D all X Cancel Woodward 47 DSS 2 Two Channel Digital Speed Switch Manual 36598 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 configuration 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 Parameter 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 DSS 2 controller To Configure the Serial Port 1 From the main menu screen choose Configure gt Custom Serial Port The application will ACT Communications Configuration Serial Controller Connection Dem

DSS-2 Two-Channel Digital Speed Switch

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