DS630 Throttle Controller USER MANUAL
Contents
1. Inc Midwest amp Dynamatic Dynamometers DS630 Throttle Controller USER MANUAL Job Model Serial www dynesystems com DPD 004 03 FROM DYNE SYSTEMS INC The DS630 Throttle Controller is an actuator throttle position controller designed to control the position of Dyne Systems Inc DS actuators as well as the older high speed and high torque actuators No other actuators are officially supported although some may work This Throttle Controller is designed to operate with the Inter Loc V Controller allowing for a user friendly interface via the DS Operator Control Station OCS The DS630 Throttle Controller is designed to operate only with an Inter Loc V Controller containing an optional throttle card Features Summary e Sub D connections are used to interface with the Inter Loc V Controller e Fault detection e g actuator stall power fail etc e Three Calibration Options Local Remote and Manual e User Friendly Interface with touch screen control position feedback and fault indications via the DS Operator Control Station OCS NOTE 7his manual is intended for use by qualified personnel only All Dyne Systems approved drawings if included and specific instructions for this equipment must take precedence over general information contained in this manual Thank you for purchasing this product from Dyne Systems Our staff is at your disposal should you need information or support that2. Power Fail o PAU Ok Feedback o Power 24VDC o Output Power 24VDC to Inter Loc V Actuator Position Feedback Common o Actuator Position Excitation 0 Power Common Button Up Button Down o Button Enter o Buton Soft Shutdown o Vols Common A 9 Table 4 3 2 Oo 2 Oo 5 2 m N a NE d 20 Position Command Common i ResetCommand L 2 10 Dyne Systems DS630 THROTTLE CONTROLLER 4 Connections DPD 006 03 Copyright Dyne Systems Inc MS CONNECTORS ACTUATOR POWER 6 Pin Male MS Connector Input Power from Inter Loc V Power Transformer Neutral 120VAC 120VAC Neu Input Power Hot 120VAC Input 120VAC Hot Input Power i i E Table 4 4 ACTUATOR MOTOR 6 Pin Female MS Connector Output Actuator Power A Actuator Armature o _ Actuator Armature 0 Positive Actuator Output Power B J 4 Nc J O O D Actuator Armature OO O E O Actuator Armature o Negative Actuator Output Power E Actuator Armature o Negative Actuator Output Power Actuator Armature o Positive Actuator Output Power Table 4 5 Dyne Systems DS630 THROTTLE CONTROLLER 4 Connections 11 DPD 006 03 Copyright Dyne Systems Inc SECTION 5 OPERATION NOTE All control of the 05630 Throttle Controller is done via the Inter Loc V O
3. Inc SECTION 3 Mounting Electrical Connections INSTALLATION 05630 Throttle Controller comes in a 3 5 h x 17 w x 15 d enclosure designed to fit into a standard 19 rack mount enclosure DS also provides rack mount brackets for ease of installation Unless previously specified the end user is responsible for providing the mounting system NOTE The DS630 Throttle Controller requires air to circulate through its enclosure for proper cooling Be sure to provide 2 3 of space at the front and rear of the enclosure to allow air flow All electrical connections should correspond with the schematic provided by DS at the time of delivery General connection information is provided to show the location of all possible connections to the DS630 Throttle Controller for pin outs of all connections reference the CONNECTIONS section SECTION 4 NOTE Only a qualified electrician should install the DS630 Throttle Controller All installations should comply with the most current version of the National Electrical Code NEC as well as all local codes and regulations NOTE Refer to Figure 3 1 for the DS630 Throttle Controller rear panel connector locations Figure 3 1 DS630 Throttle Controller Rear Panel Connector Locations Dyne Systems DS630 THROTTLE CONTROLLER 3 Installation 7 DPD 006 03 Copyright Dyne Systems Inc SECTION 4 CONNECTIONS The DS630 Throttle Cont
4. this is not a requirement Familiarity with the calibration procedure combined with feedback to the operator via the LED s on the Remote Station box ultimately allows calibration to be performed with only the Remote Station box in hand and the OCS display not visible 14 Dyne Systems DS630 THROTTLE CONTROLLER 5 Operation DPD 006 03 Copyright Dyne Systems Inc Local Calibration 1 Touch Local in the Setup Mode group This activates all on screen setup buttons 2 Touch the Lower button to begin calibration of the 0 percent throttle position The LOWER LIMIT annunciator will turn bright red to remind the operator that the 0 percent position is being established 3 Touch and hold the UP and DOWN buttons to move the throttle to the desired 0 percent position NOTE Once past the previously set limits the UP and Down buttons cannot be held to move the actuator arm they must be repeatedly touched 4 When the throttle is at the desired 0 percent position touch the ENTER button The position reading is reset to 0 percent the LOWER LIMIT annunciator turns off and the ACCEPT LIMIT annunciator will turn bright red 5 Touch the ENTER button again to accept the new lower limit setting The ACCEPT LIMIT annunciator turns off and the calibration procedure automatically proceeds to set the 100 percent position The UPPER LIMIT annunciator turns bright red 6 Touch
5. and hold the and DOWN buttons to move the throttle to the desired 100 percent position Must be between 10 000 and 42 000 counts 7 When the throttle is at the desired 100 percent position touch the ENTER button The position reading is set to 100 percent the UPPER LIMIT annunciator turns off and the ACCEPT LIMIT annunciator turns bright red 8 Touch the ENTER button again to accept the new upper limit setting All annunciators turn off and the actuator returns to the 0 percent position 9 Touch the Save button to save the calibration touch the Done button to exit without saving Remote Station Calibration Remote Station calibration is identical to Local Mode calibration except the OCS setup buttons are disabled forcing similar buttons on the Remote Station box to be used The layout of the buttons and LED s on the Remote Station box is identical to the layout on the OCS This method should always be used if available since the Remote Station box is typically located near the actuator and or throttle mechanism allowing the operator to move the actuator while simultaneously viewing the position of the throttle Remote Station calibration is selected by touching the Remote Station button in the Setup Mode group This de activates all on screen buttons forcing the use of the Remote Station box Next follow the Local Mode Calibration procedure substituting the Remote Station buttons and LED s where a
6. is not found in this manual DyneSystems Inc Midwest amp Dynamatic Dynamometers CONTROLS DYNAMOMETERS SYSTEM INTEGRATION AND TEST CELL AUTOMATION Systems Inc W209 N17391 Industrial Drive Jackson Wisconsin 53037 phone 800 657 0726 www dynesystems com Dyne Systems DS630 THROTTLE CONTROLLER Introduction 1 DPD 006 03 Copyright Dyne Systems Inc TABLE CONTENTS SECTION 1 SECTION 2 SECTION 3 SECTION 4 FROM DYNE SYSTEMS INC 1 GENERAL INFORMATION 4 SARE T et 4 REGEIVINGIINSPEGTION uu ua ukan MU 4 LI I 4 TRAINING 4 IDENTIFY YOUR 5 INSTALLATION ENVIRONMENT 6 INSTALLATION 7 e Var T HI 7 ELECTRICAL CONNECTION c cee ties ata ae 7 CONNECTIONS 8 SUB D CONNECTORS C 8 ACTUATOR ENCODER 15 FEMALE SUB D ACTUATOR POSITION FEEDBACK 8 REMOTE BASIC 15 MALE SUB D REMOTE STATION CONTROL 9 THROTTLE CONTROL 37 PIN FEMALE SUB D INTER LOC V INTERFACE 10 MS NE S 11 ACTUATOR POWER 6 PIN MALE MS CONNECTOR INPUT POWER FROM INTER LOC V POWER 5 ter 11 SECTION 5 SECTION 6 Dyne Systems 09630 THROTTLE CONTROLLER DPD 006 03 Co
7. RRANTIES EXPRESS OR IMPLIED INCLUDING WITHOUT LIMITATION THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE THE REMEDIES OF BUYER FOR ANY BREACH OF WARRANTY SHALL BE LIMITED TO THOSE PROVIDED HEREIN AND FOR DELAY OR NON DELIVERY WHICH IS NOT EXCUSABLE TO THE PURCHASE PRICE OF THE GOODS IN RESPECT OF WHICH THE DELAY OR NON DELIVERY IS CLAIMED TO THE EXCLUSION OF ANY AND ALL OTHER REMEDIES IN NO EVENT SHALL DYNE SYSTEMS BE LIABLE FOR SPECIAL INDIRECT OR CONSEQUENTIAL DAMAGES INCLUDING WITHOUT LIMITATION LOSS OF USE OR PROFITS NO AGREEMENT VARYING OR EXTENDING THE FOREGOING WARRANTIES REMEDIES OR THIS LIMITATION WILL BE BINDING UPON DYNE SYSTEMS UNLESS IN WRITING SIGNED BY A DULY AUTHORIZED OFFICER OF DYNE SYSTEMS DYNE SYSTEMS LIABILITY FOR FAILURE TO COMPLY WITH ANY WARRANTY OR REPRESENTATION HEREUNDER SHALL BE LIMITED TO THE VALUE OF THE GOODS SOLD HEREUNDER Excluding equipment made for integrated systems supplied or made by Dyne Systems Dyne Systems makes no warranty on the use of the equipment in combination with other products or in the practice of any process and if a claim suit or action is based thereon Buyer shall defend indemnify and save Dyne Systems harmless therefrom LIMITATION OF LIABILITY Dyne Systems liability for defective or nonconforming products whether based on breach of warranty negligent manufacture or product liability is exclusively limited to repair or replacement at Dyne Systems ele
8. ction of such products Dyne Systems assumes no risk and shall be subject to no liability for any damages or loss resulting from the specific use or application made of the Products Dyne Systems liability for any other claim whether based on breach of contract negligence or product liability relating to the products shall not exceed the price paid by Buyer for such Products In no event will Dyne Systems be liable for any special incidental or consequential damages including loss of use loss of profit claims of third parties or damages arising from bodily injury or death however caused whether by the negligence of Dyne Systems or otherwise EQUIPMENT MADE BY OTHERS Any items supplied that are not manufactured by Dyne Systems are covered by the original manufacturer s warranty and not by a Dyne Systems warranty BUYER SUPPLIED PRODUCT Dyne Systems accepts Buyer provided equipment as a courtesy only Dyne Systems is not responsible for determining suitability of Buyer s equipment for a particular purpose Repair or configuration of Buyer supplied equipment will be charged at Dyne Systems normal rate 18 Dyne Systems DS630 THROTTLE CONTROLLER Customer Support DPD 006 03 Copyright Dyne Systems Inc APPENDIX DEFINITIONS AND FORMULAS LAW Ohm s Law defines the relationships between P power E voltage 1 current and R resistance One ohm is the resistance value through which one volt will maintain a curre
9. d throughout the manual to remind you of the hazards that exist Know your equipment before handling or working on it Used to warn of the possibility of injury to personnel and damage to equipment Used to caution of potential hazards and unsafe practices NOTE Used for special instructions related to safety proper operation or maintenance RECEIVING INSPECTION Upon the arrival of your equipment check all items received against the packing slip to ensure the shipment is complete Then inspect for damage Any evidence of rough handling may be an indication of hidden damage Be sure to perform the following inspections 1 Inspect packaging and skid s for any mistreatment Document and photograph any signs of damage 2 Inspect housing to ensure there is no damage and that unit is intact DAMAGE CLAIMS In the event of damage report it without delay to the carrier and Dyne Systems Dyne Systems warranty policy does not cover shipping damage or lost material It is important to file a damage claim with the carrier promptly If you require assistance in settling the claim contact Dyne Systems Refer to equipment by purchase order model serial and job numbers as shown on the nameplate of the unit involved TRAINING Training programs are an essential part of safe and correct operation Training provides the know how necessary to obtain top performance from your equipment Dyne Systems recognizes this fact and offers traini
10. e actuators Be sure that the actuator in use is listed below otherwise calibration faults and other issues may occur Table 6 1 shows all three DS actuators and some of their specifications Actuator Voltage Encoder Max Move Gear Nominal Minimum Maximum Volts Rate Ratio Counts Counts Counts 200 Old High Torque Old High Speed 24 246 1 38 000 10 000 42 000 200 246 1 38 000 10 000 42 000 134 1 52 000 10 000 57 000 Figure 6 1 Dyne Systems Actuators NOTE 7he DS630 Throttle Controller will never command movement rates beyond 500 sec even though the older high speed actuators are capable of higher rates NOTE f the actuator in use is not listed above please contact DS Dyne Systems DS630 THROTTLE CONTROLLER 6 Actuator Summary 17 DPD 006 03 Copyright Dyne Systems Inc SECTION 7 CUSTOMER SUPPORT Dyne Systems Customer Support can be reached at 1 800 657 0726 or by Email at sales 9 dynesystems com Please have the serial and model numbers available for all products SECTION 8 PRODUCT WARRANTY WARRANTY REMEDIES AND LIMITATIONS Dyne Systems Inc warrants the following equipment will conform to published specifications and be free from faulty material or workmanship for the listed time period from date of shipment or onsite repair New Controls 12 Months Service Calls 3 Months Repaired Controls 3 Months This warranty covers properly installed equipment
11. ng Faults and Fault Actions please reference the Inter Loc V User s Manual Chapter 4 Controllers Section 3 3 2 page 4 40 Dyne Systems DS630 THROTTLE CONTROLLER 5 Operation 13 DPD 006 03 Copyright Dyne Systems Inc CALIBRATION Actuator calibration is a critical part of the overall operation of the DS630 Throttle Controller It is vital that the Upper and Lower limits of the actuator movement be correctly set and periodically adjusted to compensate for drift Calibration is initiated performed and saved in one of three methods via the OCS touch screen display Local Mode Calibration via the pushbuttons on the Remote Station Remote Station Calibration or manually Manual Calibration To access the calibration page 1 Press the Calibrate button on the OCS front panel 2 Touch Position on the Calibration Selection popup a The following calibration page will then appear Feedback UPPER LOWER ACCEPT FAULT Counts LIMIT LIMIT LIMIT 0 M M Lower SOFT Las SHUTDOWN Upper Move Rate 5 Direction CANCEL T d Messages Save Done Figure 5 1 0 00 UP Setup Information Which Limit Zero 0 Span 38637 Counts Remote Station Manual 3 Select the type of calibration from the Setup Mode area on the bottom left of the calibration screen NOTE It is assumed that the OCS display is visible during the calibration process however
12. ng classes on site or at the factory to educate personnel in safe operating and maintenance procedures 4 Dyne Systems DS630 THROTTLE CONTROLLER General Information DPD 006 03 Copyright Dyne Systems Inc IDENTIFY YOUR PAU The DS630 Throttle Controller was configured at DS to interface with your Inter Loc V Controller Throttle Card installed Review the diagrams and verify you have the correct configuration Note Your Inter Loc V should have a Throttle Card installed Locate the model and serial numbers on the DS630 Throttle Controller and verify that they are the same as that shown on the cover of this manual This information should be used when contacting DS customer support Dyne Systems DS630 THROTTLE CONTROLLER Identify Your PAU 5 DPD 006 03 Copyright Dyne Systems Inc SECTION 2 INSTALLATION ENVIRONMENT The DS630 Throttle Controller should be mounted so it is not exposed to sever shock and or vibrations If adverse conditions are anticipated the DS630 Throttle Controller can be mounted using vibration damping materials 1 atmosphere should be free of corrosive gases 2 The atmosphere should be free of vapors or powders that could cause fire or explosion 3 Relative humidity should be 0 to 95 non condensing 4 Temperature range should be 32 F 90 F 0 32 2 Dyne Systems DS630 THROTTLE CONTROLLER 2 Installation Environment DPD 006 03 Copyright Dyne Systems
13. nt of one ampere P Power Current D 1 Watts Amps Volts Ohms ZZ V Voltage R Resistance Dyne Systems DS630 THROTTLE CONTROLLER Appendix A 19 DPD 006 03 Copyright Dyne Systems Inc APPENDIX Degrees Centigrade CW Clockwise CCW Counter Clockwise F Degrees Fahrenheit GND Ground Input or Output i Input 0 Output JP Jumper LCD Liquid Crystal Display LED Light Emitting Diode NC Not Connected NEC National Electric Code RTZ Return To Zero SSD Soft Shutdown VAC Volts Alternating Current 20 Dyne Systems 09630 THROTTLE CONTROLLER Appendix B DPD 006 03 Copyright Dyne Systems Inc
14. perator Control Station OCS DIGITAL AND ANALOG 1 0 Inputs Outputs NOTE As stated a Section 4 all digital I O is 24VDC Positive logic The DS630 Throttle Controller is entirely controlled via digital and analog inputs These inputs are directly interfaced with and processed by the Inter Loc V Controller NOTE The SOFT SHUTDOWN button on the Remote Station is a valid active input When pressed the DS630 Throttle Controller will enable itself if not already enabled will return the actuator to the zero position and finally will disable itself The resulting SSD condition is NOT a fault however it does prevent the DS630 Throttle Control from being re enabled and must be cleared via a Reset command NOTE To minimize eliminate the effects of offset voltages at the analog position command input the DS630 Throttle Controller ignores all command voltages less than 20 mV i e 0 2 position All digital outputs are available through the Throttle Control connector these outputs annunciate the state of the DS630 Throttle Controller to the Inter Loc V Controller 12 Dyne Systems DS630 THROTTLE CONTROLLER 5 Operation DPD 006 03 Copyright Dyne Systems Inc FAULTS When a fault occurs the DS630 Throttle Controller performs one of two actions depending on the type of fault Some faults cause the actuator to return to the zero position and then disable Other faults simply disable the DS630 Thro
15. pplicable Dyne Systems DS630 THROTTLE CONTROLLER 5 Operation 15 DPD 006 03 Copyright Dyne Systems Inc Manual Calibration Manual calibration is the easiest and quickest calibration method available It can be used with or without the existence of a Remote Station box however this method is fastest if a Remote Station box is available Manual calibration is the same as the previously described position calibration methods except the DS630 Throttle Controller is disabled This allows the actuator arm to be moved manually by hand instead of using the UP and DOWN buttons The ENTER button is still active both on the OCS and the Remote Station box So when the 0 percent and 100 percent positions are set either of these ENTER buttons can be pressed to accept the respective limit Manual calibration is selected by touching the Manual button in the Setup Mode group Then follow the Local Mode Calibration procedure but move the actuator arm manually as needed NOTE For more information on all three of these calibration procedures please reference the Inter Loc V User s Manual Chapter 7 Transducers Section 5 2 16 Dyne Systems DS630 THROTTLE CONTROLLER 5 Operation DPD 006 03 Copyright Dyne Systems Inc SECTION 6 ACTUATOR SUMMARY Over the years DS has used three different actuators The latest actuator is the Standard actuator The DS630 Throttle Controller can be used with all thre
16. pyright Dyne Systems Inc ACTUATOR MOTOR 6 PIN FEMALE MS CONNECTOR OUTPUT ACTUATOR POWER 11 OPERATION 12 DIGITAL AND ANALOG ID eost 12 12 OUTPUT Gcr 12 CHR 13 PS t EE 14 LOCAL MODE CALIBRATION dus esti delis 15 REMOTE STATION CALIBRATION asas 15 MANUAL CALIBRATION 16 ACTUATOR SUMMARY 17 Table of Contents SECTION 7 CUSTOMER SUPPORT 18 SECTION 8 PRODUCT WARRANTY 18 APPENDIX A DEFINITIONS AND FORMULAS 19 OHMS LAW I S GH 19 APPENDIX B ACRONYMS 20 Dyne Systems DS630 THROTTLE CONTROLLER Table of Contents 3 DPD 006 03 Copyright Dyne Systems Inc SECTION 1 GENERAL INFORMATION Dyne Systems Inc hereafter referred to as DS is the sole Original Equipment Manufacturer OEM of the DS630 Throttle Controller This manual intended for qualified personnel only contains instructions for proper handling installation and operation of the DS630 Throttle Controller All DS approved drawings if included and specific information for this equipment must take precedence over general information contained in this manual SAFETY Read your instruction manual Electrical rotating equipment can be dangerous Prior to operation become familiar with all safety instructions and procedures WARNING CAUTION and NOTE labels are use
17. roller has three Sub D Connectors and two 6 Pin MS Connectors that interface with external devices All of the digital Inputs and Outputs I O use PLC level i e Positive 24VDC logic SUB D CONNECTORS ACTUATOR ENCODER 15 Pin Female Sub D Actuator Position Feedback masa x s s NN s Table 4 1 Dyne Systems 09630 THROTTLE CONTROLLER 4 Connections DPD 006 03 Copyright Dyne Systems Inc REMOTE BASIC 15 Pin Male Sub D Remote Station Control x 1 DO Remote Staton Power gt Baton Up 4 Remote Staton Lower Limit LED Indicator s Remote Staton Upper Limit LED Indicator s ButonDown Staton Down Buton s 590 Shutdown Remote Station Soft Shutdown Buton Table 4 2 Dyne Systems DS630 THROTTLE CONTROLLER 4 Connections DPD 006 03 Copyright Dyne Systems Inc THROTTLE CONTROL 37 Pin Female Sub D Inter Loc V Interface Positon Command Shield Actuator On P Power Common P Power Common Power 24VDC o Actuator Position Feedback o Shiel P Power Common Lamp Lower Limit Lamp Upper Limit Lamp Accept Lamp Faut Shield LK A B Postion CommandGommon TS Reset Command ESTOP
18. ttle Controller and leave the actuator position as is usually to prevent damage to the DS630 Throttle Controller After resolving the fault condition the DS630 Throttle Controller can be cleared by issuing a Reset command NOTE Detailed fault descriptions are available via the OCS display only The Actuator may remain at its previous position even after clearing and resetting e some faults Use caution when restarting the system as the throttle may still be set at the previous position Loss of Actuator Disable The actuator cable may be disconnected or damaged The actuator s encoder Encoder ILK could also be faulty Invalid Span Disable The actuator is improperly calibrated i e insufficient span A sufficient span must be between 27 000 and 42 000 counts This fault occurs only when the operator attempts to enable the DS630 Throttle Controller Successfully re calibrate the upper and lower limits to eliminate this fault Loss of PAU OK Disable Most likely a hardware fault internal to the DS630 Throttle Controller Over Temperature Over Current etc Throttle PAU Power Fail The head supply voltage has fallen below 20 VDC Verify the line voltage is at or near 120VAC NOTE 7his fault always occurs when the DS630 Throttle controller is powered down Stalled Disable Actuator movement is blocked Could also occur due to improper calibration of upper and lower limits Table 5 1 NOTE For further information regardi
19. used within specified limits and ambient conditions and is limited to repair or replacement of equipment proving defective at Dyne Systems For warranty to be valid Buyer must conform to Dyne Systems factory specifications If applicable terms of Warranty Validation and Delivery Certification must be met for warranty to be valid This warranty does not apply to experimental developmental or non standard Goods and Products which are sold as is where is Dyne Systems shall not be liable for labor costs associated with removing reinstalling or delivering any equipment Transportation costs associated with delivering products to Dyne Systems under the warranty are the responsibility of the Buyer Transportation costs associated with returning products to the Buyer under the warranty are the responsibility of Dyne Systems If warranty service is deemed necessary and product i e controls small dynamometer etc can be shipped to Dyne Systems then it is expected that product be sent to Dyne Systems however if Buyer wants warranty work to be performed onsite and Dyne Systems deems it feasible then Buyer will be responsible for travel hours and travel transportation costs Dyne Systems is not liable for costs incurred such as loss of work time or production time or for loss of profits or other damages including but not limited to consequential damage THE FOREGOING WARRANTIES ARE EXCLUSIVE AND ARE GIVEN AND ACCEPTED IN LIEU OF ANY AND ALL OTHER WA
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