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APECS® 3000 Electronic Engine Speed Governing System

1. cccccssscccccssseeccesseeeceeseeecseseecseeeeessaneeessaasees 10 OO ath F EAU E a 10 Speed Select Switch Wiring cc cceeeeeccceeeecseesseecceeeeeeeeeeseeceeeeeseeeeaeeeeeeeeessaaeaeess 11 Optional FC TC 11 TUG OV MING EE 11 Remote Status Lamp Wiring ccccccsseeecceeceeeeeeeeeceeeeeeeeeeseaeeeeeeseeeeeeesessageeeeseeas 13 Optional Feature ssiicc ce 2so2satesdecedshevatseceehscsdsasGsdandsedecedsbaiagstinahededeastedestaahseaiac 13 CHAPTER 3 CALIBRATION TOOL ACT OPERATION cesceeeeenecnseenecees 14 AGT Installation EE 14 FANG 4 elt EE 14 SEU elen EE 14 Hardware Get up 14 Software SOLU e EE 15 BGC ACTO O UO D 16 Running the ACT Software ccccccssccccceceesseceeseeeeseceeeseeeeeeeeessaaeeeeessaaaeeeees 16 Progress Display Screen ccccccceseeeccccececeeeeseeceeeeeseeeeeeeeeeeeeessaaeaeeeeeeeseesaas 16 Moving Around the Goftware 16 AGT Menus le EE 17 ACT EE 17 FUG MEM EE 18 PUDO O eae E E N E E E 18 DAVE APEC Calio TE 18 View Cal File Comments cccccceccesseeeeeeceeeeeceeeeeaeeeeeeeseaeeeeeesseaeeeeeeesaaess 20 View Text FIG ces chcacsehdenasetcadeaseleieserececseeincdianeGedscheacetadbenagenianttecseotetelsaieteedatens 20 Convert Commande 20 CONVE APECS Gal 10 Texile E 21 Conven Cal FIEt TEx esn E es acn oueeeeseg ees 21 Convert Cal File to Strategy cccccccccsssssseceeeesecseeeseeeeeeeeseseaeeeeeeeeeesssaaaeees 21 ATID AC EE 22 Change APECS Calibration ccc
2. choose Configure gt Custom Seral Controller Connection r Demo Mode Serial Port The application will C Com C EPS 1000 Cancel display the following screen Ee EE Cust APECS 3000 2 Choose a port and Click OK a i APECS 4000 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 5000 Demo Mode This mode will use a calibration file Demo 000 and use random numbers for values requested from the controller COM 1 COM 2 This mode will look for a controller attached to the selected serial port An error message will be displayed AFTER you click OK if a controller cannot be found or if the port cannot be opened COM ports outside of this range can be used by editing the default COM port registry key for this application 39 Woodward APECS 20007 Electronic Engine Speed Governing System Manual SE 4049 Help Menu The Help Menu provides access to the online user s manual and other information helpful to your use of the Calibration Tool The following commands are available under the Help Menu e Help Topics e About ACT e User s Manual Help Topics This command allows you to search for specific information by displaying software menu items or through key words 1 Click on Contents for an outline of the software applications listed by menu items 2 Click on Index
3. lt D gt for derivative gain adjustment The application will enable the gain you selected 2 Use the Up or Down arrow keys to increase or decrease the present value The arrow keys adjust the values by 0 004 New values may be typed in directly Hit lt Enter gt after you type in a value The application will save the new value in the APECS unit 3 Press the lt Esc gt to deselect the gain adjustments To Change Plot Setup This allows you to choose engine rpm desired engine speed duty cycle or any other parameter for viewing real time plots on screen Axis scales can also be adjusted to fit the parameter and or speed 1 On the Parameter Plot screen click on Configure The application will show the following screen with the current values Woodward 29 APECS 20007 Electronic Engine Speed Governing System Manual SE 4049 Plot Setup E x Plat 2 In des au ew MM Axis Max Asis Max Asis Min Asis Min 1 Avis Time Scale e sec gt Avis Sample Date fi DU m sec Plot 1 Plot 2 Use the pull down to select the desired parameter to plot Axis Min Max Enter the minimum maximum value for the parameter value X Axis Time Scale Controls how much data is displayed on the X axis This value may automatically adjust for screen resolution X Axis Sample Rate Controls how often the data from the controller is used to update the screen Data received between timer ticks is discarded 2 Clicking
4. read and observe the precautions in Woodward manual 82715 Guide for Handling and Protection of Electronic Controls Printed Circuit Boards and Modules Packing a Control Use the following materials when returning a complete control protective caps on any connectors antistatic protective bags on all electronic modules packing materials that will not damage the surface of the unit at least 100 mm 4 inches of tightly packed industry approved packing material a packing carton with double walls a strong tape around the outside of the carton for increased strength 52 Woodward APECS 20007 Electronic Engine Speed Governing System Manual SE 4049 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 of a purchase order for the item s to be repaired No work can be started until a purchase order is received NOTE We highly recommend that you make arrangement in advance for return shipments Contact a Woodward customer service representative at 1 800 523 2831 in North America or 1 970 482 5811 for instructions and for a Return Authorization Number Replaceme
5. Mode 1 in Table 3 Woodward 11 APECS 20007 Electronic Engine Speed Governing System Manual SE 4049 A toggle switch is used to select between two set TWO SPEED MODE Vbatt speeds Refer to Switch Configuration Mode 2 in Table 3 To Vbatt APECS 3000 use SA 4450 Speed Select Speed Select 2 No Connections To Ground use SA 4451 THREE SPEED MODE Vbatt APECS 3000 Part No SA 4450 is switch to Vbatt controller Part No SA 4451 is switch to ground controller A three position rotary switch is used to select To Vbatt among three set speeds use SA 4450 Refer to Switch Configuration Mode 3 Speed Select 1 Speed Select 2 FOUR SPEED MODE 4 Speed to Ground A 4 position rotary switch with two diodes is used to select among four set speeds Refer to Switch Configuration Mode 4 in Table 3 P SL in Table 3 To Ground Part No SA 4450 is switch use SA 4451 to Vbatt controller Part No SA 4451 is switch to ground controller APECS 3000 Speed Select 1 Speed Select 2 To Ground use SA 4551 4 Speed to Vbatt To Vouti Typical diodes that can Wuse SA 4450 be used with the four speed mode are 1N4001 peed Select IN4002 up to 1N4007 peea Select e 12 Woodward APECS 3000 Electronic Engine Speed Governing System Man
6. OK will save this information in the Windows Registry so that it will be remembered the next time the program is started NOTE The Calibration Wizard will automatically set up the plots if there are no saved defaults Display Faults This command allows you to display present faults in real time This means if new faults occur while you are monitoring the screen will automatically update to display the 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 To Display Faults in Real Time Current Faults Start Error Description 1 s C h oose M O n Ito r gt D l S p ay fault_flags1 1 User has not calibrated APECS unit D fault_flags1 4 actuator disconnected or short circuit Faults from the main menu De Cuentas he Beie setings st z fault_flags1 6 speed set pot out of a H fault flags z ain set nal g d The application will launch the GE bey vege th ng F fault_flags2 10 dummy 2 1 faul 1 fault_flags2 11 dummy 2 2 fault ault view The application will update the display every time the Ge Historical Fats controller sends the fault_flags status This happens several times a second 2 Click on the Pause button to stop the automatic update of this screen The text on the button will change to Start and clicking it again will re start the aut
7. Table 3 There are five switch configurations available WARMUP_TIME Length of time to hold engine at warmup speed immediately after engine has started running Seconds Setting WARMUP_TIME to zero disables the warmup feature 40 Woodward APECS 20007 Electronic Engine Speed Governing System Manual SE 4049 Table 3 Switch Configuration Models CONFIGURATION MODE DESCRIPTION A single engine speed is commanded The engine is started and transitions from crank mode to run mode The commanded engine speed will increase from SET SPEED MIN to SET SPEED WARMUP atthe RAMP_UP_RATE 1 SINGLE SPEED Engine speed remains at the warm up speed for WAR MUP_TIME seconds after which the engine speed either increases at RAMP_UP_RATE or decreases at RAMP_DOWN_ RATE to SET _SPEED_1 A switch is used to select between two set speeds The engine is started and transitions from crank mode to run mode The commanded engine speed will increase from SET SPEED MIN to SET_ SPEED WARMUP at the RAMP_UP_RATE Engine speed remains at the warm up speed for WAR 2 TWO SPEED MUP_TIME seconds after which the engine speed either increases at RAMP UD DATE or decreases at RAMP_DOWN_ RATE to the speed selected by the switch SET _SPEED_1 or SET SPEED 2 When the other speed is selected with the switch commanded engine speed is ramped to the new set speed A rotary switch is used to select among three set speeds The engine is started and trans
8. a previously saved file You may use the View Text File command to view text files 20 Woodward APECS 20007 Electronic Engine Speed Governing System Manual SE 4049 Convert APECS Cal to Text This command allows you to create a text file of APECS calibration data for viewing or printing from any text editor utility in Windows A printed copy of the calibration data can be useful for future reference To Convert APECS Calibration to Text 1 Choose File gt Convert APECS Cal to Text 2 ACT will prompt you to enter a name to save the text file Enter a file and click OK ACT will read all of the calibration values from the controller create and save a text file with the parameter names values and units then display the file using the default text viewer Convert Cal File to Text This command allows you to convert a previously saved ACT calibration file to a text file for viewing or printing from any text editor utility in Windows A printed copy of the calibration data can be useful for future reference To Convert Cal File to Text Choose File gt Convert Cal File to Text 2 ACT will prompt you to enter a name to save the text file Enter a file and click OK ACT will read all of the calibration values from the controller create and save a text file with the parameter names values and units then display the file using the default text viewer Convert Cal File to Strategy This command is used to convert old ACT
9. 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 54 Woodward APECS 20007 Electronic Engine Speed Governing System Manual SE 4049 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 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 595 We appreciate your comments about the content of our publications Send comments to icinfo woodward com Please i
10. by email or through the Woodward website e Technical Support e Product Training e Field Service Contact information Telephone 1 847 967 7730 Fax 1 847 967 7832 E mail info_niles woodward com Website www woodward com ic Technical Support is available through our many worldwide locations or our authorized distributors depending upon the product This service can assist you with technical questions or problem solving during normal business hours Emergency assistance is also available during non business hours by phoning our toll free number and stating the urgency of your problem For technical support please contact us via telephone email us or use our website and reference Customer Services and then Technical Support Product Training is available at many of our worldwide locations standard classes We also offer customized classes which can be tailored to your needs and can be held at one of our locations or at your site This training conducted by experienced personnel will assure that you will be able to maintain system reliability and availability For information concerning training please contact us via telephone email us or use our website and reference Customer Services and then Product Training Field Service engineering on site support is available depending on the product and location from one of our many worldwide locations or from one of our authorized distributors The field engineers are experienced
11. 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 sae on them and then clicking Delete or by pressing lt Del gt 4 Click OK on the comment editor or press lt Enter gt twice to save comments Click Cancel or press lt Esc gt twice to close the window without saving comments The Cal File will still be created if the comment editor is canceled 5 The following message is displayed when the file is created successfully The file name in this message is the file selected in Step 2 ACT will save the calibration data to the designated file and display Calibration Data Saved in File ABCD ACT message where ABCD is the name you entered in Step 2 NOTE The Save APECS Cal to File command stores the calibration data as an ACT file that cannot be viewed or printed directly Viewing and printing must be done from a converted text file See Convert APECS Cal to Text and Convert Cal File to Text commands Woodward 19 APECS 20007 Electronic Engine Speed Governing System Manual SE 4049 View Cal File Comments This command allows you to display the comments that are attached to a calibration file Users add comments when saving a calibration file The comments help in tracking specific engine application and environment data for which the calibration file was created To View Calibration Comments
12. conflgureation 4 75 E07 mm IA az d IF d 4 7 Fi Z Te 325 h i d SES B26 mm A IT d CFS mm A A JI dP K ie K N 3 807 CU A 3 mm3 98 4 mr 8 00 H En Violet Seed elect L Dau Zpset delect d Sr Tel lon Tx TEE Orang For Tol Controller Calibration Tool BAa 4455 Figure 8 APECS 3000 Wiring Diagram Speed Sensor Installation Guidelines There are four different soeed sensing devices that can be used with the APECS 3000 system The APECS controllers per matching sensors are e Model 3100 magnetic pickup input e Model 3200 spark ignition input e Model 3300 magneto input e Model 3400 Hall Effect input Refer to Table 2 Controller Wiring and Figure 8 Wiring Diagram for guidance in selecting the speed sensor suitable for your controller and application 8 Woodward APECS 20007 Electronic Engine Speed Governing System Manual SE 4049 For Models 3100 and 3400 the mounting of the sensor unit must be rigid excessive vibration can cause erroneous signals and unreliable performance Use twisted pair shielded wire for all soeed sensor wiring Shield should be grounded at the controller only Magnetic Pickup Used with Model 3100 Installed opposite an engine driven gear such as the flywheel it transmits a signal each time the magnetic flux path across the pole is interrupted by a gear tooth Spark Ignition Used with Model 3200 Inte
13. e Convert Cal File to Text e Convert Cal File to Strategy Save APECS Cal to File This command allows you to save APECS calibration data to a designated file The ACT uploads the calibration set from the APECS controller and saves it to a computer file This operation is usually done after the controller has been calibrated for satisfactory engine performance but can also be done at any other time The data is saved ina binary file format that is not readable To Save APECS Cal to File 1 Choose File gt Save APECS Cal to File ACT will prompt the path where the file will be saved 2 Enter a file name to save the BEE 2x calibration data to Save in ACT e ct ACT will automatically append the file extension ACT to the file name if you do not specify one Click Save or press lt Enter gt Filename My Cal Fid Save as type CAL Files ACT DI Cancel Z ACT will then read all of the current Processing Calibration Values calibration values from the controller This screen shows the progress SET_SPEED_4 18 Woodward APECS 3000 Electronic Engine Speed Governing System Manual SE 4049 x Once all the values are read ACT gt will prompt you to add comments to ef Do vou wish to edit the new Cal File Comments the ACT file to aid in later identification 3 Ifyou click Yes the comment editor screen will appear To enter comments type them one at a time and press lt Enter gt or
14. inch Actuator travel should be adjusted to assure both maximum start fuel or rated load and minimum shutdown or idle positions NOTE Ci It is beyond the scope of this manual to discuss detailed actuator selection and installation procedures for all possible applications Please contact the factory for specific information concerning your application Engine Protection Input Wiring Optional Feature The APECS 3000 controller offers an engine protection shutdown feature to safeguard against adverse operating conditions such as low oil pressure or high coolant temperature The engine protection EP input is a switched input similar to the set speed inputs and is used in lieu of set speed 4 input The 4 speed mode configuration is not available when this option is used The EP input will not interfere with variable soeed mode The engine protection input must Vbatt switch to the same potential as the APECS unit If the APECS is a Pe switch to ground unit then the engine protection input must also Speed Select 1 switch to ground Diagram at right SES e To G d shows how to wire the engine Low Oi Ke SA 4451 protection input Pressure 4th input EP To use more than one sensor simply wire the sensors in parallel Once the engine protection input is wired you must configure the following two calibration parameters to make the feature work Set ENGINE PROTECT_TIME to a
15. or Find to locate a specific topic through an alphabetical listing or by typing in a word or phrase 3 Follow the on screen commands to page through the manual About ACT This command displays the version of the calibration tool that you are currently using This information is important for tool identification purposes and for servicing support User s Manual This command accesses the User s Manual which includes comprehensive information on the APECS 3000 controller wiring diagrams ACT software menus and calibration parameters The manual may be viewed online or printed for future reference Woodward 33 APECS 20007 Electronic Engine Speed Governing System Manual SE 4049 Chapter 4 Calibration Procedures EN Calibration Guide This section explains the procedures for calibrating configuring and adjusting the various APECS 3000 features to work with your application Before proceeding make sure you have installed all the required hardware for your system and are familiar with using the APECS Calibration Tool ACT Safety Precautions The APECS 3000 is a user configurable engine speed governor and will follow your settings and commands immediately Please be aware of this when calibrating and entering values in the unit It is possible to enter values in the APECS unit that are in excess of what the engine is capable of performing and outside of safe operating range It is the user s responsibility t
16. ordinarily overspeed is not necessary It is disabled by setting OVERSPEED_ RPM to zero However if a user feels the need for a more aggressive response to an overspeed condition the overspeed diagnostic feature may be used 46 Woodward APECS 20007 Electronic Engine Speed Governing System Manual SE 4049 Actuator Output Calibration Parameter DUTY CYCLE OFFSET A constant offset added to the governor duty cycle terms to help account for the minimum duty cycle necessary to drive the actuator percent Woodward 47 APECS 20007 Electronic Engine Speed Governing System Manual SE 4049 Chapter 5 APECS Troubleshooting Procedures EN General Checklist Please follow the checklist below to troubleshoot your APECS controller We recommend using a digital multimeter capable of measuring frequency and duty cycle such as a Fluke 87 1 Check battery voltage for stability and correct value 2 Check that speed signal is at least 2 VRMS using AC volt settings on voltmeter Actuator should go to full travel during cranking Check for fault codes see Table 4 Check linkage for binding and backlash Check that actuator has sufficient force Confirm normal operation of engine under manual control NDP Ww Confirm that load e g voltage regulator on generator is not inducing instability 8 Try adjusting gains to achieve stability Status Lamp Fault Codes The APECS controller is capable of identifying certain fault con
17. the APECS controller calibration software ACT speed sensor actuator and linkage Each component contributes to the overall performance of the system and shortcomings in any of the components will detract from total system performance APECS Controller The APECS 3000 series controller is an isochronous engine governor that provides a means of controlling and limiting engine speed by adjusting the fuel control lever with a proportional actuator The APECS controller may be programmed to operate at up to four different speeds The controller is software programmable and has no manual adjustments A calibration tool ACT is used for programming configuring and adjusting the APECS 3000 controller Figure 2 APECS Controller with Calibration Tool Connector The following features are standard on all APECS 3000 models e lsochronous speed control e Variety of speed signal inputs magnetic pickup Hall Effect coil type ignition magneto ignition e Calibrations set with a personal computer e Easy to calibrate with APECS start up wizard e Calibration tool graphs engine speed on screen in real time during calibration process e All settings remain in memory during shutdown e Engine protection input protects against adverse conditions such as loss of engine oil pressure or excessive coolant temperature e Overspeed underspeed protection e PID gain adjustment allows governor response to be adjusted by user e Remote speed co
18. to select a Cal File to compare Choose a Calibration file to compare Files of type Cal Files 000 4CT x Cancel Open as read only Calibration File Comments 24 Woodward APECS 20007 Electronic Engine Speed Governing System Manual SE 4049 2 Choose a file and Click OK This screen will show the progress Processing Calibration Values OVERSPEED_RPM 3 Once all parameters have been processed a message box will list the compare results If the parameters in the file match the controller the following message box appears ACT wl AN File Matches Controller 4 Click OK to close If there were mismatches the following message will appear Compare Differences X Controller lt gt C WOODWARD ACT TOOLNAPX41MOSTEST ACT Mismatch List File Controller Units oo 0 7 Name ACTUATOR_FDBK_GAIN 0 20001 2498 NONE ACT_FDBK_KFILT 0 801 0 977 NONE AFB_LOST_DLY 21 20 ms 10 AFB_NO_AMPS 33000 0 mA APP_AD_ORH 254 1023 adents APP_AD_ ORL 10 0 adents APP_FULL_DEADBAND 6 5 adents APP_IDLE_DEADBAND 6 5 adents APP_MIN_CAL 230 0 240 5 adcnts APP_NOISE_CNT 31 30 NONE APP_RANGE_CAL 550 0 540 5 adcnts AUTOCRANK_CRANK_TIME 11 0 10 0 sec AUTOCRANK MAX TRIES 5 6 NONE AUTOCRANK NG TIVE 1 0 1 5 sec AUTOCRANK_REST_TIME 16 0 15 0 sec AUXILIARY _OUTPUT_2_ MODE 1 0 NONE AUXILIARY _OUTPUT_MODE 2 0 NONE AUX_I_LIM 121 120 a2d AUX_LAMP_INRUSH_TIME 4 3 msec 10 AUX_OUTPUT_2_RPM 1500 0 700 0 rpm AUX_OUTPUT_RPM 1501
19. warm up speed for WARMUP_TIME seconds after which the user may select a 5 VARIABLE new speed by using the switches which will either increase or SPEED decrease engine speed A brief pressing of the switch will change engine speed by one rom Holding the switch closed longer will ramp the engine speed command first at a slow rate then at either RAMP_UP_RATE or RAMP_DOWN_ RATE depending on which direction the switch is being pressed The engine speed command will never ramp above SET SPEED MAX or below SET SPEED MIN 42 Woodward APECS 20007 Electronic Engine Speed Governing System Manual SE 4049 FAQ Questions About Set Speed Calibration After a power down power up reset does APECS remember the last speed it was using No The only data APECS retains after power down are the calibration parameter settings If you are using the variable soeed mode you will have to reestablish the desired speed after the engine is restarted However if you are configured for one of the four set soeed modes then APECS will command the same speed on the next power up after an optional warm up period as long as the switches haven t been changed If using variable speed mode what is the initial speed command when the engine starts SET SPEED WARMUP Even if WARMUP_TIME is set to 0 this will be the initial engine speed command It does not change until the engine is running and the toggle switch is pressed The toggle switch has no effec
20. 0 700 0 rpm BRAKE DELAY 1 0 0 0 sec CRANK_2_RUN 1100 0 700 0 rpm CRANK_DUTY_CYCLE 1 000 0 945 7100 DERIVATIVE_GAIN 0 262 0 250 NONE DERIVATIVE_GAIN_IDLE 0 262 0 250 NONE Close Ise 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 Woodward 25 APECS 20007 Electronic Engine Speed Governing System Manual SE 4049 Change APECS Password This command allows you to add or change a password to protect certain calibration features The option is useful for example to prevent unauthorized changes to a known good calibration set in the APECS unit By default the APECS unit is not password protected To Change APECS Password 1 Choose Calibrate gt Change APECS Password You will be prompted for the current password Password Management l x Please enter the controller password E Ehange Cancel OF ae poe Enter password and click OF 2 The application will query the controller to verify that the entered password matches the current password If the password matches the Change button is enabled Password Management q Ei Please enter the controller password Change Cancel UK SE Change Hee Password Valid Click Change to change controller password 3 Click Change and the application will prompt for the new password x Enter new Password Change e Canc
21. EED_TIME Woodward 37 APECS 3000 Electronic Engine Speed Governing System Manual SE 4049 CATEGORY PARAMETER DESCRIPTION a UNDERSPEED RPM Actuator shutdown speed min Run time before UNDERSPEED_RUN_TIME underspeed is checked Delay before UNDERSPEED_ TIME Underspeed shutdown Actuator Output DUTY CYCLE OFFSET Calibration Offset to governing duty cycle Governor Gain Calibration Parameters DERIVATIVE_GAIN Engine speed governor derivative gain unitless Derivative gain is used to improve stability Increase derivative gain until response has a slight overshoot on load transients INTEGRAL_GAIN Engine speed governor integral gain unitless Integral gain is used to remove steady state errors Increase integral gain until speed begins to oscillate and then decrease until oscillation stops If oscillations do not occur bump actuator lever then decrease integral gain until oscillation stops PROPORTIONAL_GAIN Engine speed governor proportional gain unitless Proportional gain is used to improve response time A maximum amount of proportional gain should be used while still maintaining stability Increase proportional gain until speed begins to oscillate then decrease until oscillation stops If oscillations do not occur bump actuator lever then decrease proportional gain until oscillation stops ACT allows the user to adjust the P I and D gain settings and observe the response directly on scree
22. Hardware required for optional features is not provided or sold by Woodward Take adequate protection to ensure personal and equipment safety and follow the suggested installation sequence given below Install main components Review Wiring Guidelines Install Controller Install Speed Sensor Install Actuator and Linkage Install optional components hardware installation required Engine Protection Input Speed Select Switch Remote Status Lamp Detailed instructions for installation and wiring are provided in the following pages Wiring Guidelines 1 To install and wire the controller refer to Figures 7 amp 8 and Tables amp Il 2 Power leads are to be connected directly to a switched power source i e battery Use of a 10 amp slow blow fuse is recommended in the battery positive wire 3 Use proper gauges of wire as shown in Table Wire insulation should be appropriate for engine applications 4 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 7 for con troller dimensions Woodward 5 APECS 20007 Electronic Engine Speed Governing System Manual SE 4049 5 A short to ground fault of the actuator wires could result in an overspeed condition Use of convoluted tubing conduit or other wire shielding is rec ommended to minimize the likelih
23. SE 4049 W wWooDWARD APECS 3000 Electronic Engine Speed Governing System User s Manual Manual SE 4049 A A WARNING Read this entire manual and all other publications pertaining to the work to be performed before installing operating or servicing this equipment Practice all plant and safety instructions and precautions Failure to follow instructions can cause personal injury and or property damage The engine turbine or other type of prime mover should be equipped with an overspeed shutdown device to protect against runaway or damage to the prime mover with possible personal injury loss of life or property damage The overspeed shutdown device must be totally independent of the prime mover control system An overtemperature or overpressure shutdown device may also be needed for safety as appropriate CAUTION To prevent damage to a control system that uses an alternator or battery charging device make sure the charging device is turned off before disconnecting the battery from the system Electronic controls contain static sensitive parts Observe the following precautions to prevent damage to these parts e Discharge body static before handling the control with power to the control turned off contact a grounded surface and maintain contact while handling the control e Avoid all plastic vinyl and Styrofoam except antistatic versions around printed circuit boards e Do not touch the compon
24. a Saved Calibration File You may wish to calibrate additional APECS units with a saved calibration file for consistent optimized operation To Calibrate an APECS Unit with a Saved Calibration File 1 Access the Calibrate menu to activate the Download Cal File to APECS command 2 Select the appropriate file to download refer to the comment list on the right side of the screen to help identify the desired file Enter password if prompted ACT will download file calibration to APECS permanent memory 3 Repeat Steps 1 and 2 if multiple APECS units are to be calibrated NOTE Gi The APECS unit must be powered up but need not be mounted on the engine to out the calibration procedure Woodward 35 APECS 20007 Electronic Engine Speed Governing System Manual SE 4049 Understanding APECS Calibration Parameters This section provides answers to frequently asked questions about calibration parameters lists parameters and provides calibration procedures Frequently Asked Questions What is a calibration parameter A parameter is a numerical value that helps the calibrator adjust or set the APECS controller Once fixed by a calibrator the parameter is not subject to change while the system is operating APECS calibration parameters are used not only to adjust and set the controller but also to configure it properly for different applications Why do we need to calibrate the APECS system APECS 3000 is a software progr
25. alibrate a Controller Unit Using the APECS Calibration Wizard 1 From the main menu press lt C gt to open the Calibrate menu 2 Arrow down to APECS Calibration Wizard and press lt Enter gt The Wizard will inform you if the unit has been previously calibrated or not NOTE Gi Please be aware that using the Wizard will reset all existing APECS parameters If you do not intend to change all parameters do not use the Wizard Manually calibrate only those parameters you intend to change Woodward 27 APECS 20007 Electronic Engine Speed Governing System Manual SE 4049 Press lt Enter gt to continue or lt Esc gt to abort the Wizard If you press lt Enter gt the Wizard will lead you through the calibration process with a series of questions When all questions have been an swered the Wizard will ask you to confirm that the values entered are accurate 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 APECS Wizard will download the new calibration and reset all APECS parameters This will complete the APECS Wizard operation NOTE Gi The APECS Calibration Wizard only covers basic calibration It does not automatically assure optimum engine operation Please refer to APECS Calibration Procedures for more information 5 You are now ready to run your engine Press any key to go directly to the Parameter Plot
26. ammable system and has no manual adjustment Calibrating is the only means of configuring and adjusting the controller for your specific application Do need to calibrate ALL the parameters to make my system work No Two parameters PULSES PER UPDATE and PULSES DER HEN are factory set to prevent the APECS unit from calculating an engine speed and driving the actuators These two parameters must be calibrated to a non zero value before normal APECS operation can begin Other parameters are preset to values that will work with many engines and applications However it is recommended that you review all settings for your own application Is it possible to enter values in APECS in excess of what the application is capable of performing Yes While ACT the calibration tool restricts you from entering values outside of the specified range the range itself is fairly wide and it is possible to enter values in excess of what your application is capable of performing For example it is possible to command engine speeds up to 8192 rom with ACT Your engine may or may not be able to operate at this speed It is also possible to damage the generator or pump attached to your engine by commanding maximum engine speed because while the engine may be capable of performing at the rated rom the generator or pump is likely to have a lower rpm rating than the engine Furthermore there are certain parameters that are used to properly configure an applicatio
27. be below UNDERSPEED_RPM before underspeed shut down is activated msec FAQ How does Overspeed Work The APECS 3000 has the diagnostic capability to detect and react to an overspeed condition The feature uses two programmable parameters OVERSPEED RPM and OVERSPEED_TIME Overspeed feature immediately shuts off the actuator when the engine runs above OVERSPEED_RPM for OVERSPEED_ TIME OVERSPEED_TIME is used to adjust the sensitivity A large value will delay the shut down and a small value will hasten it A value as small as zero can be used which means that the first occurrence of engine speed being over OVERSPEED_RPM will result in a shut down This is too sensitive and the engine could be shut down in the unlikely event that noise on the speed signal input caused a high miscalculation of engine speed A minimum value of 250 msec is recommended The user should realistically determine an overspeed tolerance time When an overspeed condition is detected the duty cycle goes immediately to zero Hopefully this will stop the engine A fault code is generated and the LED flashes The fault will continue to flash so that the user is made aware of why the engine stopped The engine may be restarted without resetting the unit The fault will then recover and stop flashing By default overspeed is disabled This is because a properly tuned PID governor will decrease the duty cycle to the actuator any time engine speed is above the set point So
28. ccccccssseeeeeeeeeeeeeeeeeceeeeeseaeeaeeseeeeesssaaaaeees 22 Download Cal File to AE 23 Compare APECS Cal to File Cal 24 Change APECS Password 26 APECS Calibration Wand 27 PVCS TBO NST EE 28 Selen 28 Parameter PIO E 29 Woodward i APECS 20007 Electronic Engine Speed Governing System Manual SE 4049 DIS DIA e E EE 30 CO MUEOM SS WALCO xe ces srtecncs patted gaa eaten cd ec atresia 31 Parameter LIS cia sichitane ss taenc taba tines oun isladeeneelasctinn ual de rcueten satuteneeteeen iter 31 Configure Ment sssc5cc3 226t cnncctteaadedetecuadtnneictelshacenedssbaeded steeuautateadbaleiancoadsaieetedstesesee 32 COMMNGULG Se POr dE 32 ICID BET NEE 33 GcleRbelel Le 33 PDOUPAG EE 33 BE a O BEE 33 CHAPTER A CALIBRATION PROCEDURE csscssseeneenecneensneceeeeenseneeaueennes 34 calpration WIGS sss cee ses eeben 34 DAILY e e EE 34 Calibrating an APECS Un 34 Saving a Calibration Set totie ce ccccceeecceeeseeeeeeeeeseeeseeeessaeeeeeessaaeeeees 35 Calibrating an APECS Unit with a Saved Calibration Eilen 35 Understanding APECS Calibration Parameters cccccccseeeeeeeeeeeeeseeeeeeeaeeeeeas 36 Frequently Asked e e EE 36 Brea 37 Governor Gain Calibration Parameters n0annnnnnennnneneennnnnsennnnnnsrnnnennennnresennenee 38 Engine Set Speed Calibration Parameters nnnsnsennnsnseennreeernrrnnsrrrrreenrrrrrrenn 40 Eege 43 Questions About Set Speed Calibration cccccccceccccssssssssesseeeeeeeee
29. ditions and alerting the user to them A flashing LED indicates the fault conditions The current fault code list is shown in Table IV Please note the following 1 When power is first applied to the controller the LED will flash just once for one second to indicate that the LED is working If there are multiple faults the LED will flash them all If there are no faults the LED will flash once at reset and from then on indicate the detection of engine speed 4 The controller will attempt to shut down for all faults and will not permit starting after reset with faults 1 5 and 6 48 Woodward APECS 3000 Electronic Engine Speed Governing System Manual SE 4049 Table 4 Fault Codes FLASH CODE FAULT REMEDY APECS unit not calibrated Calibrate APECS unit Check parameter settings Overspeed criteria may be too sensitive Check for electrical noise entering controller Engine speed excessive i j Check wiring and connections Check case ground Make sure linkage moves freely without backlash Check tip of speed sensor Check parameter settings Engine speed unusually low Check linkage and the actuator travel Check load and make sure it is not greater than the capacity of engine Check parameter settings Engine shutdown due to engine protection input Check what may have triggered the protection input If calibration file is available download calibration file and cycle power again Factory setti
30. e Choose File gt View Cal File Ce Documents Comments fs My Network Places ICAD System Files ACT will display a list of files on the left sjoemo c00 LEE Pdf s side of the screen with file comments on the right File name Ir E e Use the Up and Down arrow keys to Fies oftype Cal Files 000 ACT z Ges highlight the desired calibration file F Open as read only ACT extension and view the Calibration File Comments comments attached to that file e 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 ea Convert Commands The Save APECS Cal to File command discussed earlier stores the calibration data as an ACT file that cannot be viewed or printed directly Viewing and printing must be done from a converted text file There are two convert commands available with ACT Convert APECS Cal to Text and Convert Cal File to Text The difference between the two commands is as follows 1 In Convert APECS Cal to Text operation the calibration set that is converted is from the APECS unit 2 In Convert Cal File to Text operation the calibration set that is converted is from
31. eeeeees 43 Speed Input Configuration Parameters n0annnnnnennnneneennnnnnennnnesrrnnnnnnennnnenennenne 43 FAO EE 44 Questions About PULSES DER REN 44 Engine Start Calibration Parameters cccccccsssseeeeecaeeseeeeeeeeeeeeeeesseaeeeeesesaaees 45 Diagnostics Calibration Parameters nn0annnnnnennnnnnennnnnneenrnensrnreresrnnrrensrnrreenenne 45 FAO eegene eege eegene 46 How does OverSpeed Work 46 Actuator Output Calibration PDarameier 47 CHAPTER 5 APECS TROUBLESHOOTING PROCEDURES 1sscceseseeseeeserees 48 General CMe C KS Tessie sca ye Sk tle es hati ea ae a Ie eat Sd 48 Status Lamp E IEN 48 Glossary of Technical LEO een enges eebe 50 CHAPTER 6 SERVICE OPTIONS 0cccceeseeeeseeeeeeeeeneeeeaseeeeneeeeaeeeeaneeeeneeeenes 51 Product Service ODIOMS EE 51 Heplacement Evchange 51 FatRate ee 52 Flat Rate Hemanutachure 52 Returning Equipment for Repair c ccssccccssseeecceseecceseeecseseecseeseeessaseesssaaeees 52 Packing a alte EE 52 Return Authorization Number carranna ieee Ae 53 EE EE Ee 53 HOW tO GOntact Woodward EE 53 ENGMESINO Re 54 TECHIAICAlASSISTANG S E 55 ii Woodward APECS 20007 Electronic Engine Speed Governing System Manual SE 4049 Chapter 1 Understanding the System eee ee eee ee System Basics APECS is an acronym for Advanced Proportional Engine Control System It provides a means of controlling engine speed by adjusting the fuel control lever with an actuator The hea
32. el OK Status Password Change Mode 26 Woodward APECS 20007 Electronic Engine Speed Governing System Manual SE 4049 4 Enter the new password It should be x one word no spaces and up to 11 characters long Once entered click OK The application will prompt to reenter the password to make sure Eer that it was typed in properly j Ch C OF 5 Re enter the password and click OK If Status Dap Cancel ok the two entries of the new password are Password Change Mod n equal the new password will be encoded and saved in the controller Passwords are upper and lower case sensitive After changing your password please record it in a safe place for future reference To revert to no password protection change APECS password to peg which is the default password ACT Operation with the New Password Once a password is added or changed the following calibration features become password protected Change APECS Calibration Download Cal File to APECS Change APECS Password APECS Calibration Wizard At the start of any future sessions ACT will always prompt you to enter the new 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 APECS Calibration Wizard The APECS Calibration Wizard is an interactive guide to help you get your controller unit up and running as quickly as possible To C
33. ents 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 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 2004 All Rights Reserved APECS 20007 Electronic Engine Speed Governing System Manual SE 4049 Contents BEE CHAPTER 1 UNDERSTANDING THE SYSTEM en eK KKK KEREN RER ENKER KEREN R KEN 1 Se 1 AFEC OC ONTON cee ean enn Onn eege 2 Calibration TOONMAG RM 3 See RE 3 PCT ON ilastanacaadatnedavates E E E E E E 3 Bale EOE E E E E EE E A E EE S T E E 4 CHAPTER 2 INSTALLING THE HARDWARE ccceccsccecsscecnscecneceenecuseeeueenaens 5 KREIEN 5 Wining Lengths EE 6 Controller Installation EE 7 CONTOS ge E 7 Speed Sensor Installaton 8 EI ee 8 Actuator amp Linkage Installation cccccccssseceeeseeeeeseeseeeeaeeeeesseeeeessaseeesaaneeeenaaeees 9 Engine Protection Input Wiring
34. ese parameters is optional CRANK_SPEED Speed transition point indicating engine has gone from no start mode to crank mode rom In no start mode the Actuator is not driven In crank mode control is open loop the actuator is driven with a fixed duty cycle This parameter is preset to a value that will work with most engines and applications Entering new values for these parameters Is optional RUN_SPEED Speed transition point indicating the engine has gone from crank mode to run mode rom In run mode control is closed loop the actuator is driven as necessary to maintain the set desired engine speed Diagnostics Calibration Parameters ENGINE PROTECT TIME The amount of time spent with the engine protection input made before the actuator is shut down msec Setting ENGINE PROTECT_TIME to a non zero value activates the engine protection option The engine protection input is a switched input such as a low oil pressure sensor It is connected to both speed switch inputs on the APECS 3000 see speed switch wiring diagrams in Chapter 2 Using the EP input precludes the use of set speed 4 switch configuration 4 All other switch configurations are possible If the engine has been running longer than WARMUP_TIME and the engine protection input has been made longer than ENGINE_PROTECT_TIME then the actuator is shut down and a fault is generated The lamp on the APECS unit will flash to indicate the fault The fault is cleared whe
35. face Module liege Shoal Ingart Green Valet Speed Select L iny ip Select 2 Yellow k tery Ie Figure 10 ACT System Set Up Software Set Up ACT software can be automatically installed on your hard drive from the CD ROM supplied with the kit To install the software on your hard drive follow the procedures below NOTE Make sure power to the PC and the APECS unit is off when making connections The engine may or may not be running 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 or setup program 2 Follow the prompts from the install program You may select the default directory or specify your own 3 When installation is complete you may access the ACT software from the Start Menu or create your own shortcut 4 The set up is now complete and you are ready to run ACT e Torun the ACT software please refer to Basic ACT Operation below e Put the original CD ROM in a safe place in case the files on your hard drive are damaged or lost Woodward 15 APECS 20007 Electronic Engine Speed Governing System Manual SE 4049 Basic ACT Operation Running the ACT Software The ACT software is fairly easy to use Follow the procedures below to run the program Make certain that the APECS i controller is powered up and connected to the compu
36. 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 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 Woodward 21 APECS 20007 Electronic Engine Speed Governing System Manual SE 4049 Calibrate Menu The Calibrate Menu allows you to perform operations related to APECS calibration The following commands are available e Change APECS Calibration e Download Cal File to APECS e Compare APECS Cal to File Cal e Change APECS Password e APECS Calibration Wizard Cl These commands can be password protected to prevent unauthorized calibration changes See Change APECS Password for more information Change APECS Calibration The Change APECS Calibration command allows you to calibrate configure and adjust various parameters associated with the APECS controller APECS 3000 is a programmable engine governor Changing APECS calibration parameters is the means to configure the APECS cont
37. gure 4 Magnetic Pickups Available from Woodward Actuator The actuator converts a pulse width modulated signal received from the controller to an output shaft position proportional to the duty cycle of the pulse width modulated signal The actuator is mounted on the engine and connected to the control lever by a mechanical linkage Figure 5 Woodward Actuators for APECS Controllers NOTE On spark ignition engines the control lever is usually the throttle lever On compression ignition engines diesels the control lever is usually one of the mechanical governor levers either shutoff or governor Woodward 3 APECS 20007 Electronic Engine Speed Governing System Manual SE 4049 Linkage The linkage connects the actuator shaft to the engine control lever A good linkage allows for misalignments and contributes to accurate stable and responsive performance with minimal play or friction Figure 6 Linkage Hardware available from Woodward NOTE The scope of this manual does not include selection and installation of speed sensors actuators or linkages that Woodward offers for use with the APECS system Information is available on our website at www woodward com 4 Woodward APECS 20007 Electronic Engine Speed Governing System Manual SE 4049 Chapter 2 Installing the Hardware When installing the APECS hardware be aware that some of the options selected may also require hardware setup see list below
38. he returned core could be delayed and cause additional charges to be applied Woodward 51 APECS 20007 Electronic Engine Speed Governing System Manual SE 4049 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 s attach a tag with the following information name and location where the control is installed name and phone number of contact person complete Woodward part number s and serial number s description of the problem instructions describing the desired type of repair CAUTION To prevent damage to electronic components caused by improper handling
39. ing 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 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 t
40. itions from crank mode to run mode The commanded engine speed will increase from SET SPEED MINto SET SPEED WARMUP at the RAMP_UP_RATE Engine speed remains at the warm up speed for WAR 3 THREE SPEED MUP_TIME seconds after which the engine speed either increases at RAMP_UP_RATE or decreases at RAMP_DOWN_ RATE to the speed selected by the rotary switch SET_SPEED_1 to SET _SPEED_3 When another speed is selected with the switch the commanded engine speed is ramped to the new set speed Woodward 41 APECS 20007 Electronic Engine Speed Governing System Manual SE 4049 A rotary switch with two diodes is used to select among 4 set speeds The engine is started and transitions from crank mode to run mode The commanded engine speed will increase from SET SPEED MIN to SET SPEED WARMUP atthe RAMP_UP_RATE Engine speed remains at the warm up speed for WARMUP_TIME 4 FOUR SPEED seconds after which the engine speed either increases at RAMP_UP_RATE or decreases at RAMP_DOWN_RATE to the speed selected by the rotary switch SET _SPEED_1 to SET SPEED_4 When another speed is selected with the switches the commanded engine speed is ramped to the new set speed A momentary switch is used to ramp desired engine speed either up or down The engine is started and transitions from crank mode to run mode The commanded engine speed will increase from SET SPEED MIN to SET SPEED WARMUP at the RAMP_UP_RATE Engine speed remains at the
41. lation ACT Kit Contents ACT is used for programming configuring and adjusting and monitoring the APECS controller with your personal computer The ACT kit contains the following e Software CD ROM e Interface module e RS 232 connecting cable e CD ROM Installation Guide Set up Requirements Hardware Requirements e IBM compatible personal computer equipped with a CD ROM drive and a serial port with DB 9 connector capable of 9600 baud communication e Windows software 95 98 Me 2000 XP e 64 MB of available RAM memory and a hard disk with at least 2 0 megabyte of free disk space e SVGA capable video card and monitor capable of 256 colors and 800 x 600 display Software Requirements e CD ROM of calibration tool software to run on your personal computer CD supplied with ACT kit Hardware Set up To connect your PC to the APECS 3000 unit a standard RS 232 nine pin cable and a proprietary interface module is required Both are included in the ACT kit NOTE Make sure power to the PC and the APECS unit is off when making connections The engine may or may not be running Connect one end of the RS 232 cable to your PC s COM port Connect the other end of the cable to the interface module Now connect the interface module to the APECS 3000 unit via the connector on the harness 14 Woodward APECS 3000 Electronic Engine Speed Governing System Manual SE 4049 Com Port LerZreller SS fe al ae Cable Inter
42. lects the purpose 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 Save in ACT e ct Be engine speeds awf E error codes avf for a file name of a previously saved View Configuration Select the desired file and click Open The View Configuration will be updated with the saved parameters Filename JM ien ot The ACT application will always 7 Weg recall the default set of plot Save as type ACT View Setup Files Ca d Cancel p ina ae ere re eee EEN 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 Woodward 31 APECS 3000 Electronic Engine Speed Governing System Manual SE 4049 NOTE Only one of the parameter view screens can be monitoring the controller at once Configure Menu Configure Serial Port This command allows you to designate the proper COM port for your PC to enable communication between the ACT and the APECS controller To Configure the Serial Port 1 From the main menu screen ACT Communications Configuration 2 x
43. log output the higher the duty cycle the higher the equivalent analog output Speed Sensor Device such as a magnetic pickup that senses engine speed 50 Woodward APECS 20007 Electronic Engine Speed Governing System Manual SE 4049 Chapter 6 Service Options EH 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 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 minimiz
44. mplete Reading Calibration Values from controller Please wait RESET_SPEED_2 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 Use mouse to select or move around the menu Use left mouse to execute a command or accept a condition Use function key lt F1 gt for HELP A HOT key highlighted character in a menu item can also be used to access or activate a menu or sub menu e g File use lt ALT gt lt F gt Click on the x box in the upper right hand corner to exit ACT 16 Woodward APECS 20007 Electronic Engine Speed Governing System Manual SE 4049 ACT Menus amp Options ACT Menu Structure The ACT has five main menus File Menu Calibrate Menu Monitor Menu Configure Menu and Help Menu with several options available under each A complete discussion of all ACT menus and options is presented in the following pages Save APECS Cal to File View CAL File Comments EE CS P a S Woodward 17 APECS 20007 Electronic Engine Speed Governing System Manual SE 4049 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 APECS Cal to File e View Cal File Comments e View Text File e Convert APECS Cal to Text
45. n Entering incorrect values for these parameters will result in improper configuration and may make the engine run at maximum throttle Entering values outside of safe operating range can result in serious physical injury and or damage to the equipment 36 Woodward APECS 3000 Electronic Engine Speed Governing System Manual SE 4049 List of Parameters CATEGORY PARAMETER DESCRIPTION SH DERIVATIVE GAIN Speed stability Governor Gain INTEGRAL_GAIN Steady state speed Calibration PROPORTIONAL GAN Engine speed ramp RAMP Up RATE Engine speed ramp up rate SET SPEED 1 Engine set speed 1 1800 SET SPEED 2 Engine set speed 2 1900 ee SPEED 3 Bon set speed 3 E Engine Set SET SPEED4 SPEED 4 Engine setspeed4 _ set speed 4 2500 Speed SET SPEED MAX Maximum 2500 Calibration increment speed decrement speed speed 1 2 3 4 multispeed WARM_UP_TIME Time spent at e warm up speed No of pulses in PULSES PER REV each sampling Speed Input period Configuration No of pulses until next engine speed update PULSES _PER_SAMPLE Kickoff duty cycle for open loop 0 95 cranking No start to crank ain CRANK SPEED mode transition speed Crank to run mode See transition speed 700 Switch delay before engine protection shutdown OVERSPEED RPM Actuator shutdown speed max Delay before overspeed 150 shutdown CRANK_DUTY_CYCLE 50 Diagnostic Calibration ENGINE_PROTECT_TIME 1000 OVERSP
46. n in the form of a real time plot The plots on the following page illustrate the various conditions a user may encounter while tuning an application Although conditions may vary according to application and nature of load these plots are typical of what is often observed Figures 11 15 illustrate less desirable conditions often encountered while tuning an application and suggest probable causes Figure 16 shows a plot of a properly tuned application Although conditions may vary according to application and nature of load this plot is typical of what is often desired 38 Woodward APECS 3000 Electronic Engine Speed Governing System Manual SE 4049 PID Gain Settings Response Plots ACT allows the user to adjust the P I and D gain settings and observe the response directly on screen in the form of a real time plot The plots on the following page illustrate the various conditions a user may encounter while tuning an application Although conditions may vary according to application and nature of load these plots are typical of what is often observed Desired RPM Desired RPM K Actual RPM A TIME Figure 12 PID Gains Too High Actual RPM Ki Actual RPM F Desired RPM p Figure 13 Integral Gains Too Low Figure 14 Derivative Gains Too High Desired RPM Remove Load Actual RPM J Add Load Figure 15 Integral Gains Too High or Figure 16 Desirable Response Derivative Gains Too Low NOTE Ci Exces
47. n the engine is restarted Woodward 45 APECS 3000 Electronic Engine Speed Governing System Manual SE 4049 set ENGINE PROTECT_TIME to zero to disable the engine protection option OVERSPEED_ RPM Critical engine speed used for overspeed protection rom Set OVERSPEED_RPM to zero if overspeed protection is not desired Normal closed loop governing will decrease the duty cycle to the actuator any time engine speed is above the set point Overspeed protection immediately shuts off the actuator when an overspeed condition is detected Engine speed must be brought back to zero before the actuator is driven again Setting OVERSPEED_RPM to zero disables the overspeed protection feature Default value 0 OVERSPEED_ TIME Amount of time engine speed must be above OVERSPEED RPM before overspeed engine protection is activated Seconds UNDERSPEED_ RPM Minimum engine speed used for underspeed shut down rom Normal closed loop governing will increase the duty cycle to the actuator any time engine speed is below the set point Underspeed shut down immediately shuts off the actuator when an underspeed condition is detected Engine speed must be brought back to zero before the actuator is driven again Setting UNDERSPEED RPM to zero disables the underspeed protection feature UNDERSPEED_ RUN TIME Amount of time the engine must be in run mode before underspeed shut down is activated sec UNDERSPEED_TIME Amount of time engine speed must
48. nclude 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 ANSI RAB QMS FM 57982 BS EN ISO 9001 1994 6 March 2001 Za EN fe P E well m J Woodward has company owned plants subsidiaries and branches as well as authorized distributors and other authorized service and sales facilities throughout the world Complete address phone fax email information for all locations is available on our website 04 9 M
49. nded for either traditional coil and distributor ignition or distributorless ignition systems Magneto Ignition Used with Model 3300 Typically found on small 1 and 2 cylinder engines Hall Effect Used with Model 3400 Located next to an engine driven gear NOTE It is beyond the scope of this manual to discuss detailed speed sensor selection and installation for all possible applications Please contact the factory for specific information concerning your application Actuator amp Linkage Installation 1 Select actuator with sufficient force to move the fuel control lever from minimum to maximum fuel position The controller has a working range of 9 30 Vdc However the actuator must be selected for either 12 or 24 Vdc charging system 2 Select or design a bracket that correctly aligns the actuator shaft and control lever and is able to withstand the vibration level of the engine or application 3 The linkage must have minimal friction binding and backlash The bracket and linkage should be designed to use as much of the actuator travel as possible 4 Fasten actuator to bracket and bracket to engine Attach necessary linkage between actuator shaft and fuel control lever Move linkage end to end to confirm correct travel and adjust length if needed Woodward 9 APECS 3000 Electronic Engine Speed Governing System Manual SE 4049 5 Connect actuator wires use twisted pair with more than 1 twist per
50. ngs lost ae If controller still does not work or if no calibration file is available consult factory Electrical noise may be entering controller Check wiring shielding and connections to APECS unit failed controller Cycle power to engine If controller still does not work consult factory Woodward 49 APECS 20007 Electronic Engine Speed Governing System Manual SE 4049 Glossary of Technical Terms ACT All Purpose Calibration Tool Software PC software program for configuring and calibrating the APECS controller Actuator Device that converts an electrical signal from the APECS controller to an output shaft position APECS Advanced Proportional Engine Control System Engine governing system developed by Woodward Cal File File containing APECS calibration data Cal Tool Version The version of calibration tool software in use Calibration Process of configuring and adjusting the controller to work with a specific application Calibration Wizard Interactive software guide to help you set up basic calibration and get the controller in operation quickly Control Strategy The version of software residing in the controller Duty Cycle Percentage of time a pulse width modulated owm signal remains on Parameter Numerical value that helps the user calibrate the APECS controller PWM Pulse Width Modulation Means of simulating analog output with a digital device The PWM duty cycle determines the equivalent ana
51. non zero value to enable the feature This is the time in milliseconds that the engine protection input must be made before the actuator is shut down The time you set it to will be dependent on the signal source and the tolerance to the fault condition Set WARMUP_TIME to an appropriate value This is the length of time in seconds to hold engine at warm up speed immediately after engine has started running An engine protection shutdown condition is not triggered until the engine has been running longer than WARMUP_TIME An engine shutdown condition occurs when the engine has been running longer than WARMUP_ TIME and the engine protection input has been made longer than ENGINE PROTECT_TIME At this point the actuator is shut down duty cycle goes to zero and the lamp on the APECS unit flashes code 4 The fault is cleared when the engine is restarted you do not have to reset the APECS unit To disable the engine protection feature set ENGINE _PROTECT_TIME to 0 See Chapter 4 Diagnostic Calibration Parameters 10 Woodward APECS 20007 Electronic Engine Speed Governing System Manual SE 4049 Speed Select Switch Wiring Optional Feature The APECS 3000 controller offers a speed select option for multiple speed settings This is a convenient feature for customers who need more than one speed for engine governing i e idle soeed power speed setting or low power high power setting To incorporate this option determine the s
52. nt 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 distributor or service facility For worldwide directory information go to www woodward comi ic locations Woodward 53 APECS 20007 Electronic Engine Speed Governing System Manual SE 4049 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
53. ntrol available with external switches o Preprogram up to four discrete speeds and set ramp rates between speeds or o Manually increase decrease engine speed at preset rates e Operates on 12 and 24 volt systems e Compatible with all Woodward proportional actuators o Woodward APECS 3000 Electronic Engine Speed Governing System Manual SE 4049 Calibration Tool ACT ACT is a PC personal computer based software calibrating and monitoring tool ACT is designed specifically for use with engines equipped with the APECS 3000 controller The tool can be run on any IBM compatible computer that meets the requirements listed in Chapter 3 under ACT Installation Once the APECS 3000 controller has been programmed ACT may be disconnected The APECS 3000 unit will continue to operate normally with ACT either connected or disconnected Calibration Tool 7 2 Figure 3 Calibration Tool ACT Software CD ROM Speed Sensor APECS 3000 monitors engine speed continuously Engine speed may be sensed by monitoring the frequency of spark events in spark ignition engines or through the use of a sensor that detects the passing of teeth on an engine driven gear e g flywheel Four versions of APECS 3000 are available each intended for use with a specific type of engine speed sensing Model 3100 magnetic pickup Model 3200 spark ignition system Model 3300 magneto ignition system Model 3400 Hall Effect input Fi
54. o be accurate when entering data into the APECS or the ACT Entering values outside of safe operating range can result in serious physical injury and or damage to the equipment or application WARNING An overspeed shutdown device independent of the APECS system should be provided to prevent loss of engine control that may cause personal injury or equipment damage Calibrating an APECS Unit Once the system set up is complete it is fairly easy to calibrate an APECS 3000 controller Before proceeding with calibration please ensure that the controller unit is connected to the COM port and powered Follow the steps below for calibrating your APECS controller unit 1 Ifan icon for the Calibration Tool exists double click on it to start the ACT software 2 If no icon exists click on the Start button highlight Programs find the ACT software and click to start it 3 Make sure the COM port designation in ACT matches the serial port on the back of your PC Follow the procedure outlined in the Configure Menu to change the COM port assignment if needed 4 If you wish to use the Wizard for basic calibration refer to APECS Calibration Wizard The Wizard is an interactive guide to help you get your controller running as quickly as possible 5 Beyond basic calibration there are many parameters associated with APECS that can help enhance the performance of your engine Read the section on Understanding APECS Calibra
55. omatic updating NOTE If any other screen requests data from the controller while this screen is updating this screen will automatically Pause 30 Woodward APECS 3000 Electronic Engine Speed Governing System Manual SE 4049 Control Strategy This command allows you to check the version of the control strategy in use This information may be needed for strategy identification purposes and for future updates Parameter List The Parameter List screen allows the user to adjust which parameters are displayed on the Parameter View display To Display the Parameter List CalFieName Best SH EE View List Information bo may T On View List 1 Choose Monitor gt Parameter DE y e List from the main menu eon eaten Se 2 The F5 F6 keys will res backup advance through the coat list Press F9 or click on On Gs View List to toggle the selected CG amp_timer Open S parameter on the Parameter en d BS es View screen F5 PREVIOUS F6 NEXT F9 ADD REMOVE ON VIEW ESC CANCEL EDIT CLOSE 3 Click on the x in the title bar or press lt Esc gt to close the screen Edits are not 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 Type in a file name that ref
56. ood of mechanical damage to these wires Cautious routing of actuator wires is critical to avoid sharp edges pinching and wear 6 Elevated resistance in wires or terminations can result in limited current to the actuator which will prevent full actuator travel To avoid these prob lems it is important to use good quality terminations and proper crimping technique Terminations must be impervious to moisture to prevent shorts and corro sion 7 Use shielded cable for external speed signal source Shields should be connected to the battery ground wire at one end only Wiring Lengths Excessive resistance in the wiring will result in insufficient force from the actuator Such increased resistance can result from too much wire length inadequate wire gauge or poor connections The following table shows the recommended gauges and maximum lengths of connecting wires for different size APECS actuators Wire length is the total length to and from used to connect the actuator to the controller and the controller to the system power NOTE All system wiring should be twisted pair and shielded preferably foil shielded Table 1 System Wiring e ETTE 50 mm ETTI 50 mm ETTE 00 mm o ege 20 m 33tt 10m 10 m 22t 6 7m 6 7 m oe 46 ft 14 m 23 ft 7 m 15 ft 4 6 m 0300 46 ft 14 m 23 ft 7 m 15 ft 4 6 m The controller has a working range of 9 30 Vdc However the ac tuator must be selec
57. peed mode desired based on your application The five modes available are Single Soeed Two Speed Three Speed Four Speed or Variable Speed After determining the speed mode select the switch hardware best suited for your application Switch hardware is not provided or sold by Woodward Choose a switch designed for low currents 5 to 20 mA Avoid choosing higher current devices that rely on the current to clean the switch contacts A dry circuit switch is recommended The speed select switch is typically mounted on the control panel but can be mounted in any other suitable location Use the accompanying diagrams as a guide for wiring the selected switch to your controller NOTE Controllers are available with either switch to battery or switch to ground input for the speed select switches Part No SA 4450 is switch to Vbat controller for magnetic pickups Part No SA 4451 is switch to ground controller for magnetic pickups Once the speed select switch is wired you need to calibrate Engine Set Speed Calibration parameters to make the feature work Please refer to Table 3 to configure the appropriate parameters according to the selected speed mode Switch Wiring SINGLE SPEED MODE Vboatt CS 3000 No switch is needed Use either switch to Vbatt SA 4450 or switch to ground SA 4451 controller Speed Select 1 M No Connections Speed Select 2 m No Connections Refer to Switch Configuration
58. ration Parameters PULSES PER SAMPLE and PULSES PER DEN are factory set to prevent the unit from calculating an engine speed and driving the actuator These two parameters must be calibrated to a non zero value before normal APECS operation can begin PULSES PER SAMPLE The number of pulses used to calculate engine speed PULSES _PER_SAMPLE is factory set to prevent the unit from calculating an engine speed and driving the actuator This parameter must be calibrated to a non zero value before normal APECS operation can begin Woodward 43 APECS 20007 Electronic Engine Speed Governing System Manual SE 4049 In PULSES PER_SAMPLE the fewer the pulses the faster the update rate the greater the pulses the greater the averaging effect on calculated engine speed This number is typically chosen to be the number of pulses in one engine revolution or the number of pulses in one engine combustion event whichever is less For example if the speed wheel has 96 teeth and the engine has 4 cylinders then there are 48 teeth per combustion event each combustion event takes 1 2 engine rev For spark ignition engines this number must be between 1 and 4 and is typically set at 1 PULSES PER_REV The number of teeth on the engine speed pickup wheel mag pickup and Hall Effect sensor inputs or the number of spark pulses per engine rev ignition input To figure out the pulses per revolution you must determine the kind of speed signal input u
59. refore the signal from the ignition will have one pulse per engine revolution PULSES PER DEN 1 44 Woodward APECS 20007 Electronic Engine Speed Governing System Manual SE 4049 With multi cylinder engines using a distributor the primary ignition signal will have one pulse for every cylinder firing event Since each cylinder is fired every 2 revs PULSES DER HEN number of cylinders 2 PULSES PER_REV must be an integer no half pulses allowed The ignition signal from a 3 cylinder engine will have 3 pulses per 2 engine revs which works out to 1 5 pulses per engine rev To work around this situation assign PULSES PER HEN 3 Then the calculated engine speed will be exactly half actual speed If the engine is operating at 1800 rpm displayed engine speed will be 900 rom Therefore all set soeeds must be half of the actual target speed CAUTION If you forget and set the desired speed to 1800 rpm the engine will speed up to 3600 rpm in order to reach the target Engine Start Calibration Parameters CRANK_DUTY_ CYCLE The fixed duty cycle used to drive the actuator when the engine is cranking percent May be calibrated to a maximum duty cycle for diesel engines that require full rack for Starting or a minimum duty cycle for some spark ignition engines that require closed throttle for starting This parameter is preset to a value that will work with most engines and applications Entering new values for th
60. rogramming multiple APECS units for a particular application The downloaded file may have been previously configured and calibrated for satisfactory engine performance with another APECS unit To Download a Cal File to APECS Choose a Calibration file to download S 21 1 Choose Calibrate gt Download Lookin oske BC ER Cal File to APECS The following 3 screen allows you to select a Cal file to download File name Open Files of type cal Files 000 4CT gt Cancel Open as read only Calibration File Comments 2 Choose a file and Processing Calibration Values click OK The following screen will SE show the progress ACT A The calibration File was downloaded successfully NOTE During the Download Cal File to APECS operation the user may encounter a situation where the Cal File password is different from that of the APECS unit If this happens please refer to the steps below to complete the download operation Woodward 23 APECS 20007 Electronic Engine Speed Governing System Manual SE 4049 To Download a Cal File to APECS with a Password Different from that of the APECS Unit Whenever the APECS password is added or changed the new password is stored in the unit as well as in any calibration file saved after the change During a Download Cal File to APECS operation if the password stored in the calibration file matches the password in the unit ACT
61. roller for specific engines applications and environments and for adjusting PID gains The calibration parameters have been organized into categories for your convenience Browse through the categories to view the specific parameter you want to change or adjust Some parameters must be set before the engine can run Other parameters can be adjusted while the engine is running See List of Parameters in Chapter 4 All adjustments are stored immediately in non volatile memory in the APECS unit The APECS controller will retain the changes even if power is lost or the ACT is disconnected To Change APECS Calibration Parameters 1 Choose Calibrate gt Change APECS Calibration 2 Set the View Filter to select a group of parameters 3 Use F5 F6 to scroll through the list 4 To change the highlighted parameter Enter the new value in the New Value field Press lt Enter gt The new value is written to the controller and then read back with the result placed in the APECS Value field 5 Press lt Esc gt to exit 29 Woodward APECS 20007 Electronic Engine Speed Governing System Manual SE 4049 Download Cal File to APECS The Download Cal File to APECS command allows you to download the entire calibration set from a file to the APECS permanent memory This is a convenient one step method for e Reverting back to a known good calibration set after experimenting with new calibration settings e P
62. rpm rpm Damm The application will read the previously Comigwe Mrs PS vient bes saved configuration and request the _SavetoFie DERIVATIVE GAIN bm 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 PC is very busy the timer accuracy will vary therefore the screen and generated data files should be considered as reference only 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 PID Gain Adjustments from Plot Display Screen After initial calibration most engines require only a minor adjustment to PID gains to fine tune the system to its optimum level ACT provides a convenient means of adjusting the PID gains directly from the Plot Display screen To Make PID Gain Adjustments from Plot Display Screen 1 Press the letter lt P gt for proportional lt l gt for integral or
63. rt of the system is a powerful microprocessor based controller that processes the signal received from a speed sensor and compares it to the desired speed setting The output of the controller is a pulse width modulated signal that drives a precision proportional actuator connected to the engine s fuel control lever The actuator converts the signal to an output shaft position proportional to the duty cycle of the pulse width modulated signal The APECS system provides isochronous engine governing i e engine speed is maintained at the commanded setting regardless of load through a wide speed range APECS is suitable for use on both compression ignition diesel and spark ignition gasoline CNG LPG engines Woodward developed the APECS system for a variety of on and off highway applications Typical applications include generator sets compressors construction machinery and farm vehicles WARNING An overspeed shutdown device independent of the APECS system should be provided to prevent loss of engine control that may cause personal injury or equipment damage ENGINE PRO PORTDNAL ACTUATOR ED SIGNAL APECS CONTRO LIER CALBRATDN TOO L 4 aa POW ER IN Figure 1 APECS Engine Control System Woodward 1 APECS 20007 Electronic Engine Speed Governing System Manual SE 4049 System Components The five main components of the system are
64. screen where you can adjust the PID gains Monitor Menu The Monitor Menu allows you to observe engine and APECS 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 i e engine speed in real time To View Parameter Values in Real Time 1 Choose Monitor gt Parameter View Gg EZE The application will launch the view ee een PS NENE screen The screen automatically starts reading values from the controller and displaying the values To stop the updating click on Stop The button name will then change to Start Clicking it again will start updating again NOTE If any other screen is opened that requires communication with the controller while the screen is updating the Parameter View screen will be automatically stopped 28 Woodward APECS 20007 Electronic Engine Speed Governing System Manual SE 4049 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 PROPORTIONAL_GAIN Boo engine_
65. sed on your application Magnetic Pickup Input or Hall Effect Sensor Pulses per revolution number of teeth on the flywheel Woodward Mini Gen Signal Generator Pulses per revolution 0 5 x drive ratio if Mini Gen is driven at other than crankshaft speed Spark Ignition Input Pulses per revolution 1 for single cylinder engine with magneto and one wasted spark Pulses per revolution number of cylinders 2 for multi cylinder engine with distributor FAQ Questions About PULSES PER REV How does PULSES PER REN work when using the ignition signal for engine speed When an ignition signal is used to detect engine speed the input pulses relate directly to cylinder firing events rather than teeth on a flywheel The controller measures the time between the input pulses from the ignition To accurately calculate engine speed it must know how many ignition pulses are occurring in each engine revolution this is PULSES DER DEN The number of ignition pulses per engine revolution will vary depending on the engine type Factors that must be known include how many cylinders the engine has whether there is a distributor and if a waste spark is generated Are there any general guidelines Yes Single cylinder engines typically use a magneto with a firing spark and a wasted spark The firing spark occurs at the end of the compression stroke once every 2 engine revs The wasted spark occurs at the end of the exhaust stroke 360 later The
66. sive friction and slop in the linkage are primary contributors to poor governor stability If it is not possible to stabilize engine performance check smoothness of the linkage Woodward 39 APECS 20007 Electronic Engine Speed Governing System Manual SE 4049 Engine Set Speed Calibration Parameters RAMP_DOWN RATE Rate at which commanded engine speed decreases from one Set point to a lower set point rom second RAMP_UP_RATE Rate at which commanded engine speed increases from one set point to a higher set point rom second SET SPEED 1 Preset engine speed 1 rom Used when SWITCH_CONFIGURATION 1 4 SET SPEED 2 Preset engine speed 2 rom Used when SWITCH_CONFIGURATION 2 4 SET SPEED 3 Preset engine speed 3 rom Used when SWITCH_CONFIGURATION 3 4 SET SPEED A Preset engine speed 4 rom Used when SWITCH_CONFIGURATION 4 SET SPEED MAX Highest engine soeed command possible when using pushbutton switches to ramp engine speed up rom SWITCH CONFIGURATION 5 SET SPEED MIN Lowest engine speed command possible when using variable soeed mode to ramp engine speed down rpm SWITCH CONFIGURATION 5 SET SPEED WARMUP Engine speed set point used immediately after engine has started running rom SWITCH_CONFIGURATION This parameter is used to let the software know how the user has configured the speed switch inputs See Chapter 2 Calibrate SWITCH CONFIGURATION according to the selected speed mode see
67. t when the engine is not running If using the 4 speed modes what is the initial soeed command when the engine starts That depends on your use of a warm up speed If you re using a warm up speed enabled by setting WARMUP_TIME to a non zero value then the first speed commanded will be SET SPEED WARMUP If you are not using a warm up speed disabled by setting WARMUP_TIME to zero then the first speed commanded is selected by the speed switches Can command the engine to stop without powering down APECS Yes if you are using 2 3 or 4 speed mode Simply set one of the set speeds to 1 When you select that speed with the switch the engine will follow the command to 1 Usually powering off the APECS unit shuts down the engine and the throttle is immediately closed However if you command a shutdown with the switch and the ramp down rate is set low the engine will be stopped in a soft shutdown manner When the engine starts does the desired engine speed jump right to the initial speed command No For a smoother start desired engine speed ramps to the initial soeed command from SET SPEED MIN SET SPEED _ MIN is independent from the other 4 set speeds It may be set to any value above or below the other speeds The recommended value for SET SPEED MIN is the low idle speed of the engine Remember that SET SPEED MIN is also the minimum variable speed commanded when lowering engine speed with the toggle switch Speed Input Configu
68. ted for either 12 or 24 Vdc charging system 6 Woodward APECS 3000 Electronic Engine Speed Governing System Manual SE 4049 Controller Installation Controller Wiring The controller can be installed in the engine compartment maximum temperature 185 F 85 C 4 15 1207 mm Sa BE 826 mm al ee LD SOOT Red Batery Black gorread nannan Synchro Start wit t 203 2 mm RODUCTS INC wg Actuator e htBlk Bhe Magnet Advanced porc nalEnghne Cont een Gem PE kup Vikt SpeedSekct 1 Gray SpeedSekct2 Orange Figure 7 APECS 3000 Dimensions Table 2 Controller Wiring MODEL 3100 MODEL 3200 MODEL 3300 MODEL 3400 sem 1 ee BATTERY Black Black Black Black ACTUATOR White Black White Black White Black White Black MAGNETIC IGNITION MAGNETO HALL PICKUP INPUT EFFECT Blue SPEED SIGNAL Blue Blue Coil A Blue Signal Green INPUT Green Green Coil B Black Ground Tan Coil C Red Sensor power 3 SPEED SELECT Gray Gray Gray Gray 2 ACT Yellow Tx Yellow Tx Yellow Tx Yellow Tx CONNECTOR Orange Rx Orange Rx Orange Rx Orange Rx Optional Woodward 7 APECS 3000 Electronic Engine Speed Governing System Manual SE 4049 Speed Sensor Input Magnetic Pickup Spark Ignition l Twisted Falr A hlelded Coble Froaportiorial ctuator Switch Fuse OC amp To ground ar what kont depending on APECS I controller
69. ter s COM Copyright C 2004 Woodward Inc This software and the accompanying written matenals ae copyrighted po rt This software may not be copied in whole o n pait j tegatdless of the form of media without prior wintten consent of Woodward Inc f i f h i b e Woodward Inc makes no warranties express of implied with respect to the software or its quality a n ICO n O r t e ca ratlo n too performance merchantability or fitness for any particulas H H purpose The software ts bcensed and delivered as is exists double click on it to start the i Any damages loss of property or other costs resulting ACT softwa re T h e icense screen from the use of this software is the sole responsiblity of the indnvidual or organization using will be displayed when the ACT is launched You must either accept the terms or Cancel which exits the Se application SE If no icon exists click on the Start button highlight Programs find the ACT software and click to start it Default is Woodward then select APECS EPS Calibration Tool Make sure the COM port designation in ACT matches the serial port on the back of your PC Follow the procedure outlined in the Configure Menu to change the COM port assignment if needed 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 co
70. tion Parameters and decide on the parameters you would like to adjust 34 Woodward APECS 20007 Electronic Engine Speed Governing System Manual SE 4049 6 Access Change APECS Calibration option from the Calibrate menu and select the desired parameter from the appropriate category Adjust the value of the parameter as needed 7 Repeat Step 5 until all desired parameters have been adjusted and satisfactory engine performance has been achieved 8 You do not need to save the new calibration settings All settings are automatically saved in the controller and remain in memory after shutdown Saving a Calibration Set to File After satisfactory engine performance is achieved it is recommended that you save the calibration set to a file e A saved file allows you to experiment with other calibration settings and still be able to recall the saved calibration set e A saved calibration set can be used for configuring additional APECS units To Save a Calibration Set to File 1 Access the File Menu to activate the Save APECS Cal to File command Enter a file name to save the calibration data to a designated file When prompted to edit the comment list enter information that will help you keep track of specific engine application and environment data associated with the file 4 ACT will save the calibration set and automatically append the file extension ACT to the file name Calibrating an APECS Unit with
71. ual SE 4049 VARIABLE SPEED MODE A momentary switch s used to Vbatt ramp desired engine speed Ji either up or down APECS 3000 To Vbatt use SA 4450 See Switch Configuration Mode 5 in Table 3 speed Select 1 speed Select 2 To Ground use SA 4451 Part No SA 4450 is switch to Vbatt controller Part No SA 4451 is switch to ground controller Remote Status Lamp Wiring Optional Feature A remote status lamp can be wired to the serial communication connector on the controller without the interface module refer to Chapter 2 This allows the user to install the status lamp in an easily visible location while allowing the controller to be mounted elsewhere To wire the status lamp use a high impedance lamp LED with series resistor and connect it to the Vbatt pin red wire in corner pin A and the Tx pin Yellow wire in corner pin D of the calibration tool connector NOTE The calibration toolis not available for use while the remote status lamp is connected see Chapter 5 Status Lamp Fault Codes for further information Remote Stotys Lamp Controller Pin D Yellow Wire r Speed Signal S nput Violet Speed Salact 1 ry dpeed Select 2 Yelle 1 Savi Drange k Tool Figure 9 Remote Status Lamp Hook Up Woodward 13 APECS 20007 Electronic Engine Speed Governing System Manual SE 4049 Chapter 3 Calibration Tool ACT Operation eee ACT Instal
72. will readily download the calibration to the APECS unit However if the password stored in the calibration file does not match the password in the APECS unit ACT will alert you of a password mismatch Please follow the steps below to complete the download operation 1 When a password mismatch is detected the ACT displays a message Cal File password differs from that of the APECS unit Download the Cal File password to the APECS unit 2 If you answer Yes to this message see note below the calibration file will be downloaded and the password in the APECS unit will be changed to match the password stored in the calibration file 3 If you answer No to this message the calibration file will still be downloaded but the password in the unit will remain unchanged NOTE Gi Before answering Yes to the message make sure you know the password in the calibration file If you do not know the password you will not be able to access the password protected features under the Calibrate menu Please see Change APECS Password command for more information on password protection Compare APECS Cal to File Cal This command lets you check the differences in calibration sets between a saved file and the APECS unit The feature is useful for example to ensure that the saved file matches the calibration in the APECS unit To Compare APECS Cal to File Cal 1 Choose File gt Compare APECS Cal to File Cal This screen allows you

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APECS® 3000 Electronic Engine Speed Governing System