DSS-2 Two-Channel Digital Speed Switch
Contents
1. condition regardless of Forward or Reverse configuration the LED will be off Table 2 Fault Codes FLASH Channel 1 Set Condition Engine rom has exceeded Channel 1 speed Overspeed setpoint and CHNL_1_CONFIG 7 1 Channel 2 Set Condition Engine rom has exceeded Channel 2 speed Overspeed setpoint and CHNL_2CONFIG 7 1 a Engine Protection Set Condition Engine Protection switch activated Disappearance of speed signal No speed signal within LOSS_ TIME of Set Condition powerup OR No speed signal within AUTOCRANK _ NS_ TIME of autocrank There have been AUTOCRANK_MAX__ Overcrank No autocrank TRIES attempts to start engine and engine has not started Loss of Speed Signal Defaults to Channel 1 Set Pot He minimum Consult factory out of range speed Defaults to Channel 2 Set Pot _ minimum Consult factory out of range speed Controller failed Consult factory Woodward 6 Parameter PULSES PER REV must have a non zero value Enter the number of teeth DSS 2 i l i Uncalibrated No operation per engine rev if you wish to work in units of RPM or enter a value of 60 if you wish to work in units of Hz Application Note 36599A DSS 2 Two Channel Digital Speed Switch Woodward 7 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 WwooDWARD PO Box 1519 Fort Col2. 36599A DSS 2 Two Channel Digital Speed Switch Chapter 3 Calibration eee nn ar 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 Apply power to controller All three LEDs should turn on for one second indicating normal operation 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 Adjust speed setpoints until desired set soeeds are achieved Red LEDs should illuminate when set speeds are reached 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 Speed switching will occur at 70 of the actual set speed ACT Calibration With the addition of the All purpose Calibration Tool ACT computer interface Woodward P N SA 5206 the user can adjust the following features Frequency range for each channel factory set to 2500 5000 Hz Standard or reverse relay logic factory set to standard relay logic Reset mode Auto Manual or Latched factory set to auto Engine protection set factory set to go to set mode
3. 9 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 standards 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 It is also printed in User Manual 36598 which can be accessed online at www woodward com Woodward i Application Note 36599A DSS 2 Two Channel Digital Speed Switch 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 yo
4. W wWooDWARD Application Note VM woopwaRrD DSS 2 Channel Digital Speed Switch P N 8HO0 100 DSS 2 Two Channel Digital Speed Switch Installation Guide Application Note 36599A 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 pa
5. dward Application Note 36599A DSS 2 Two Channel Digital Speed Switch Chapter 1 General Information rrr ee ee The DSS 2 is a two channel electronic speed switch 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 The DSS 2 monitors engine rpm 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 has two multi turn potentiometers for soeed setpoint adjustment A serial interface is provided for additional adjustments with the All purpose Calibration Tool ACT DSS 2 can be re configured with the ACT to act as a glow plug controller or engine autocrank controller 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 Specifications Woodward P N 8800 1001 Electrical Power Input 9 30 Vdc Reverse polarity protected Electromagnetic Compatibility See Regulatory Compliance on page i Operating Current Both Channels On 12 V 100 mA 24 V 100 mA Both Channel
6. hole 4 Tighten terminal with a small blade screwdriver Refer to Figure 2 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 Woodward 3 Application Note 36599A DSS 2 Two Channel Digital Speed Switch 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 Power DC Jit mmi Lra Em Calibration Tool Setup Solenoid or other device 10 A Max Solenoid or other device 10 A Mak Grd Pin 7 y Ey TAD Find een Channel 2 Adjust DSS Controller Channel 1 Adjust Manual Reset se Verity Switch j p Figure 2 DSS 2 Wiring Diagram 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 4 Application Note
7. lins 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 12 M
8. on engine protection switch input Autocrank controller can reassign output channel to work as an engine autorcrank controller Glow plug control can reassign output channel to work as a glow plug controller CAUTION 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 Woodward Application Note 36599A DSS 2 Two Channel Digital Speed Switch Chapter 4 Diagnostics The DSS 2 is equipped with three LEDs one green and two red The green status LED on the DSS 2 can be used for diagnosing a variety of problems e When the DSS 2 is powered up all three LEDs will turn on for one second then turn off If they do not the DSS 2 is either not receiving power or it is completely non functional e lf a fault condition exists the green status LED will flash a code that indicates the nature of the fault Refer to the table below The ACT can also be used to look up current and historic faults e lf there are no faults the green status LED will turn on continuously when the DSS 2 receives a valid signal from the magnetic pickup If it does not then there is not a valid signal The red channel LEDs indicate the condition of the assigned channel e When the channel is in the Set condition regardless of Forward or Reverse configuration the LED will be on e When the channel is in the Reset
9. rts Observe the following precautions to prevent damage to these parts e Discharge body static before handling the control with power to the control turned off contact a grounded surface and maintain contact while handling the control e Avoid all plastic vinyl and Styrofoam except antistatic versions around printed circuit boards e Do not touch the components or conductors on a printed circuit board with your hands or with conductive devices IMPORTANT DEFINITIONS WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION indicates a potentially hazardous situation which if not avoided could result in damage to equipment NOTE provides other helpful information that does not fall under the warning or caution categories A 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 Application Note 36599A 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 198
10. s Off 12 V 50 mA 24 V 50 mA Resistive Load 1 to 10A Relay Contact Ratings 28 Vdc nducive toad TIOGA 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 Manual or with PC based All purpose Calibration Calibration Tool ACT SA 5206 Weight 0 38 lbs 0 17 kg Woodward 1 Application Note 36599A DSS 2 Two Channel Digital Speed Switch Chapter 2 Installation CAUTION Take adequate protection to ensure personal and equipment safety and follow the suggested installation sequence given below Refer to Figures 1 amp 2 to install the system and subcomponents 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 1 for controller dimensions Dimensions in inches Dimensions in are in millimeters DJ In nn nlna nlna n Q175 4 4mm 2 PLACES 4 lt z A 0 z 4 88 22 3mm Figure 1 DSS 2 Dimensions Woodward 2 Application Note 36599A DSS 2 Two Channel Digital Speed Switch Wiring DSS 2 has thirteen Euro style screw terminals for e Battery Positive and Negative 9 30 Vdc Reverse voltage protected e Two form C relays 10A continuo
11. ur 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 static 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 Do not touch the electrical conductors the connectors or the components with conductive devices or with your hands e When replacing a PCB keep the new PCB in the plastic antistatic protective bag it comes in until you are ready to install it Immediately after removing the old PCB from the control cabinet place it in the antistatic protective bag CAUTION To prevent damage to electronic components caused by improper handling read and observe the precautions in Woodward manual 82715 Guide for Handling and Protection of Electronic Controls Printed Circuit Boards and Modules Woo
12. us 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 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 All purpose Calibration Tool ACT to cover 10 10 000 Hz or operate in units of rpm 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 Input 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 Use insulated automotive grade wiring minimum 18 AWG or 1 mm for all connections Shielded wiring is recommended for the MPU To use the external connections 1 Loosen the terminals with a small blade screwdriver 2 Strip wire 3 Insert wire into terminal
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