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EPS 1000 Manual

1. Start Clicking it again will start updating again NOTE If any other screen is opened that requires communication with the controller while the screen is updating the Parameter View screen will be automatically stopped Woodward 48 EPS 1000 Engine Equipment Protection System Manual SE 4051 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 The application will read the previously saved configuration and request the controller to start sending the parameter values The controller sends the data to the PC at a rate that varies with the number of parameters being monitored The application uses the Windows timer functionality to update the screen at the specified rate Note that if the PC is very busy the timer accuracy will vary therefore i ss morrow se geen ene ST the screen and generated data files should Ges prp Pom Sod SS b QERMATIVE_GAN be considered as reference only Ee Se 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 fu
2. 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 X AN File Matches Controller Woodward 45 EPS 1000 Engine Equipment Protection System Manual SE 4051 4 Click OK to close If there were mismatches the following message will appear Compare Differences Controller lt gt C WOODWARDNACT TOOL APX41MOSTEST ACT Mismatch List Z Nane File Controller Units ACTUATOR_FDBK_GAIN 0 20001 0 72498 NONE ACT_FDBK_KFILT 0 801 977 NONE AFE_LOST_DLY 21 20 ns 10 AFB_NO_AMPS 33000 APP_AD_ORH 254 1023 adents APP_AD_O 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 i1 0 10 0 sec AUTOCRANK MAX TRIES 5 6 NONE AUTOCRANK_NS_TIME 1 0 1 5 sec au IME 16 0 15 0 sec av OUTPUT_2_MODE 1 0 NONE AUXILIARY_OUTPUT_MODI 0 NONE AUX I 121 120 a2d LAMP_INRUSH_TIME 3 AUX_OUTPUT_2_RPH 1500 0 700 0 rpm UX_OUTPUT_RPM 1501 0 700 0 rpm BRAKE_DELAY S CRANK_2_RUN 1100 0 700 0 rpm CRANK_DUTY_CYCLE 1 000 0 945 100 DERIVATIVE_GAIN 0 262 0 250 NONE DERIVATIVE GAIN_IDLE 0 262 0 250 NONE Close You may select Save to File if you would like to save a permanent r
3. Index 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 may be viewed online or printed for future reference Woodward 52 EPS 1000 Engine Equipment Protection System Manual SE 4051 Chapter 5 Service Options Product Service Options The following factory options are available for servicing Woodward equipment based on the standard Woodward Product and Service Warranty 5 01 1205 that is in effect at the time the product is purchased from Woodward or the service is performed e Replacement Exchange 24 hour service e Flat Rate Repair e Flat Rate Remanufacture If you are experiencing problems with installation or unsatisfactory performance of an installed system the following options are available e Consult the troubleshooting guide in the manual e Contact Woodward technical assistance see How to Contact Woodward later in this chapter and discuss your problem In most cases your problem can be resolved over the phone If not you can select which course of action you wish to pursue based on the available services listed in this section
4. Protection Switch A enable Disable CHNL_3_ OP_MODE Channel 3 operating mode Standard relay logic CHNL_3_ RESET Reset mode Automatic 80 25 EPS 1000 Engine Equipment Protection System Manual SE 4051 Time speed must be below Seay RESET_ 0 65535 ms 0 0 ms R SPEED 3 for reset to occur RESET _ SPEED 3 Reset speed 0 16383 8 rpm 0 0 rpm Time speed must be above SET_ SET_ SPEED 3 DELAY 3 before the 0 65535 ms 0 0 ms channel will go to the set condition SET_ Speed set i SPEED 3 point in RPM 0 16383 8 rpm 1 1 rpm Time window ae ree 0 254 x 10 ms 50 500 ms OUT signal detection Speed above NOSTART __ f 2 CRANK which crank 0 16384 rpm 50 50 rpm is assumed KE Pulses per INPUT PULSES evoluti n SR j PER_REV teeth PULSES_ GC ee 0 255 o o UPDATE p SPEED_ TYPE Speed type 0 MPU Switch A will EP A be enabled ENABLE above set 0 16383 8 rom 0 0 rpm RPM EP A ENAB LE BM Engine rpm must exceed EP A EP A ENAB 0 sec ENGINE RUN TIME LE_RPM for 0 8191 9 sec 0 PROTECTION e EP A RUN_ TIME seconds Duration that contacts EP A must remain i TIME closed open 0 65535 ms 50 50 ms to detect a fault Woodward 26 EPS 1000 Engine Equipment Protection System Manual SE 4051 Switch B will EP RB be enabled ENABLE above set 0 16383 8 rom 0 0 rpm RPM EP_B ENAB LE
5. 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 1 Choose File gt View Cal File Comments Lee Desktop My Documents ACT will display a list of files on Ke the left side of the screen with file GT comments on the right EF Pafs File name 2 Use the Up and Down arrow keys m to highlight the desired calibration file ACT extension and view the I Open as read only Calibration File Comments comments attached to that file 3 Click OK or Cancel to close Comment Viewer The comments are created or edited when the files are created View Text File This command is a convenient way to view text files Choose File gt View Text File ACT will prompt for a text file to view Select a file and click OK ACT will open the selected file with the default viewer for that file type PONS Convert Commands The Save EPS 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 EPS Cal to Text and Convert Cal File to Text The difference between the two command
6. the EPS 1000 will flag a fault code 7 User has not calibrated Speed Switch The EPS 1000 will not function with this fault To figure out the pulses per revolution you must determine the kind of speed signal input used on your application Magnetic Pickup Input or Hall Effect Sensor Pulses per revolution number of teeth on the flywheel Woodward Mini Gen Signal Generator Pulses per revolution 0 5 x drive ratio if Mini Gen is driven at other than crankshaft speed 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 Woodward 17 EPS 1000 Engine Equipment Protection System Manual SE 4051 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 PER 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 gener
7. EPS Unit with a Saved Calibration File 1 Access the Calibrate Menu to activate the Download Cal File to EPS command Woodward 12 EPS 1000 Engine Equipment Protection System Manual SE 4051 2 Select the appropriate file to download refer to the comment list on the right side of the screen to help identify the desired file Enter password if prompted 3 ACT will download file calibration to EPS permanent memory 4 Repeat Steps 1 and 2 if multiple EPS units are to be calibrated NOTE The EPS unit must be powered up but need not be mounted on the engine to carry out the calibration procedure EPS Wizard Calibration is simple when using the EPS Wizard provided in the calibration software When the calibration tool is first started it will query the EPS 1000 for its status and automatically invoke the Wizard if it senses that the EPS has not been calibrated The Wizard can be re entered at any time from the Calibrate Menu The Wizard begins by asking the user questions about the speed input signal such as the type of sensor and the number of pulses per engine revolution Next the Wizard requests information regarding the desired configuration of each of the three speed channels If the channel is to be configured as a speed switch it will ask questions regarding the desired reset mode as well as the set and reset criteria e g set speeds engine equipment protection switch influence etc If the channel is
8. Manual SE 4051 How the EPS 1000 Works Programmable Features The EPS 1000 is a programmable three channel equipment protection module designed to perform a variety of functions simultaneously It is suited for engine equipment protection sequenced operations and critical timing applications It can also be used for unattended engine starting using autocrank and glow plug functions Rather than using an array of potentiometers or DIP switches to configure the three channels the EPS 1000 is programmed by a serial link to a PC type computer This provides more flexibility and ensures that settings will not be tampered with All settings are stored in non volatile ROM and do not require battery backup Once the EPS 1000 has been configured the PC may be disconnected Channel Configuration The EPS 1000 has one speed input but can control up to three on board relays or channels The three channels can be configured independently to set and reset at various speeds For example Channel 1 could be configured to disengage the starter at 700 rpm while Channel 2 engages a PTO device at 1500 rpm and Channel 3 provides overspeed engine shutdown at 2500 rpm Each relay is a single pole double throw SPDT relay with common C normally open NO and normally closed NC contacts Contacts are rated at 10 amps Set vs Reset Speed switches make frequent use of the terms Set and Reset The Reset condition or state is that
9. RM Engine rpm must exceed EP B EP_B ENAB RUN TIME LE_RPM for 0 8191 9 sec 0 0 sec ER BRUN TIME seconds Duration that contacts EP_B_ must remain S TIME closed open 0 65535 ms 50 50 ms to detect a fault Switch C will EP_C_ be enabled ENABLE above set 0 16383 8 rom 0 0 rpm RPM EP_C_ENAB LE RPM Engine rpm must exceed EP C EP_C_ENAB RUN TIME LE_RPM for 0 8191 9 sec 0 0 sec EP_C_RUN_ TIME seconds Duration that contacts EP_C_ must remain 0 65535 ms 50 50 ms TIME closed open to detect a fault Time delay LOSS after start 0 8191 sec 5 5 sec TIME enabled Switch to ground or SE switch to battery voltage f Switch to Bit 0 EP_A 0 ground Bit 1 EP_B 0 Switch to ground Switch to Bit 2 EP_C 0 ground Multiplier for TEST_ set speed 0 1 0 7 SE VERIFY_K reduction in i default verify mode Woodward 27 EPS 1000 Engine Equipment Protection System Manual SE 4051 AUTOCRAN K Woodward AUTOCRA NK Autocrank CONFIG configuration Disable Bit 0 EP_A 0 EP A d Disable Bit 1 ER BR 0 EP B Disable Bit 2 EP_C 0 EP C AUTOCRA NK_ CRANK Crank time 0 31 9 sec 10 10 sec TIME Delay after AUTOCRA start switch NK_ before DELAY beginning of 0 8191 9 sec 0 0 sec TIME the crank sequence AUTOCRA Maximum NK_ number of MAN crank rest 0 299 1 1 cycle TRIES cycles Maximum time after ween Zuel Nk the lo G will 0 31 9 sec 1 1 sec NS TIME ed wait to detect an engi
10. a magnetic pickup input with 30 teeth 1 Ignition System sensor detects engine speed from coil type ignition system Note Even when configured for an ignition system the EPS 1000 may not be compatible with all ignition types 2 Hall Effect Sensor EPS_TIMEOUT EPS _TIMEOUT specifies the delay in counts of 10 msec to detect loss of speed once the speed signal has been observed After the delay the engine speed will be reset to zero The EPS Wizard will help configure this parameter Range 0 254 Recommended value 50 500 msec at high frequencies 200 2000 msec at low frequencies Woodward 18 EPS 1000 Engine Equipment Protection System Manual SE 4051 NOSTART_2_CRANK Engine speed in rpm above which Crank mode is assumed This parameter is automatically configured by the EPS Wizard It is also the default soeed when a speed pulse has first been detected but not yet calculated Range 0 16384 Recommended value 50 at high frequencies minimum frequency 5 at low frequencies Engine Protection Calibration The EPS 1000 can interface with up to three switched type devices that may be used to indicate engine status e g water temperature oil pressure It is assumed that a contacts closed switch status indicates a fault condition In order to accommodate devices such as oil pressure switches which indicate a fault condition when the engine is off it is possible to specify an enable rom and delay which will wait until
11. be configured to look at one two or all three of the EP switches and go to a set condition in the event of a detected fault 4 Start Switch Can be used to force a channel to the set state when the start switch is in the OFF position 5 Manual Reset Switch Can be used to force channels to the reset state and clear fault conditions 6 Test Verify Switch Can be used to reduce set and reset speeds to confirm speed switch operation at safer engine speeds Auxiliary Outputs The EPS 1000 has two auxiliary outputs AX1 and AX2 to power remote indicator lamps or relays AX1 is on when engine speed is sensed and AX2 flashes when a fault condition is detected Both AX1 and AX2 are low side drivers with current limiting capability The AX outputs will turn off if currents in excess of 200 mA are sensed This should be sufficient current for a small incandescent lamp or automotive relay Indicator Lamps LED s The EPS 1000 is equipped with four LED s one green and three red All LED s will be turned on for one second following power up as a lamp test and as an indication of normal operation Green LED The green LED is an engine status indicator and functions as follows OFF No engine speed ON Engine speed sensed Flashing Fault present Red LED s The red LED s are each assigned to a speed switch channel e When achannel is configured as a speed switch its LED will be illumi nated when the channel relay i
12. 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 files for use with controllers that have a different control strategy version ACT will 1 Parse through all of the calibration parameters in the old ACT file 2 Search for the same calibration parameters in the new ACT file and assign values from the old calibration To Convert a Cal File to a New Strategy 1 Choose File gt Convert Cal File to Strategy 2 ACT will prompt you to enter a name to save the text file Enter a file and click OK ACT will read all of the calibration values from the controller create and save a text file with the parameter names values and units then display the file using the default text viewer Woodward 41 EPS 1000 Engine Equipment Protection System Manual SE 4051 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 EPS Calibration The Change EPS Calibration command allows you to calibrate c
13. email us or use our website and reference Customer Services and then Product Training Field Service engineering on site support is available depending on the product and location from one of our many worldwide locations or from one of our authorized distributors The field engineers are experienced both on Woodward products as well as on much of the non Woodward equipment with which our products interface For field service engineering assistance please contact us via telephone email us or use our website and reference Customer Services and then Technical Support Woodward 56 EPS 1000 Engine Equipment Protection System Manual SE 4051 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 ha
14. not match the password in the EPS 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 EPS unit Download the Cal File password to the EPS unit 2 If you answer Yes to this message see note below the calibration file will be downloaded and the password in the APECS unit will be changed to match the password stored in the calibration file 3 If you answer No to this message the calibration file will still be downloaded but the password in the unit will remain unchanged NOTE Before answering Yes to the message make sure you know the password in the calibration file If you do not know the password you will not be able to access the password protected features under the Calibrate menu Please see Change APECS Password command for more information on password protection Woodward 44 EPS 1000 Engine Equipment Protection System Manual SE 4051 Compare EPS Cal to File Cal This command lets you check the differences in calibration sets between a saved file and the EPS unit The feature is useful for example to ensure that the saved file matches the calibration in the EPS unit To Compare EPS Cal to File Cal 1 Choose File gt Compare EPS Cal to File Cal This screen allows you to select a Cal File to compare EE Ai EECH
15. 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 EPS 1000 Engine Equipment Protection System Manual SE 4051 Contents eT CHAPTER 1 GENERAL INFORMATION ssecceseeeeeeeeeseneeeeeeeeeeeeeneeeeeeeeneeeeeees 1 System Components AA 1 EPS 1000 Controller siini ERARAS 1 Calibration Tool Kit CT 1 Speed RETTEN 2 EIERE Ee 2 ee We le 3 Dimensions amp Mounting cccceeeeeceeeeeeeeeee cee eeceaeeeeaeeseeeeesaaesseaeeseeeeesaeeseaaeeeenees 4 Reversible Frame ccccccccecsescececseeeeessesaeeeeseesaeeeseeeaeeescesaeeesesaeeesesenaeeseseaas 4 How the EPS 1000 WorkS s sssrssseernnsssrenscennnnisnknnnan ARANAN KANAANAN ARAANEEAANAN NRAN ARANKR REAREA 5 Programmable Features eriin aa 5 Channel Configuration 0 cccccecceee
16. the engine has been running above the rpm for a period of time before looking for the fault condition In order to avoid effects due to contact bounce and vibration a minimum contact closure time may be specified Both switch to ground and switch to battery voltage devices can be accommodated Calibration Parameters Needing Configuration EP_A_ENABLE_RPM Engine rpm must exceed EP_A_ENABLE_RPM before a switch fault can be detected Range 0 16383 8 rpm Specify 0 for those inputs that should not be dependent upon rpm ER A RUN TIME Engine rpm must exceed EP_A_ENABLE_RPM for ER A RUN TIME seconds before a switch fault can be detected Range 0 8191 9 sec EP_A TIME Duration that contacts must remain closed to detect a fault This delay will occur after any delay imposed by EP_A_ENABLE_RPM and EP_A_RUN_TIME Range 0 65535 msec ER RB ENABLE_RPM Engine rom must exceed EP_B_ENABLE_RPM before a switch fault can be detected Range 0 16383 8 rpm Specify 0 for those inputs that should not be dependent upon rpm ER RB RUN TIME Engine rpm must exceed EP_B_ENABLE_RPM for ER BRUN TIME seconds before a switch fault can be detected Range 0 8191 9 sec EP_B TIME Duration that contacts must remain closed to detect a fault This delay will occur after any delay imposed by EP_B_ENABLE_RPM and EP_B_RUN_TIME Range 0 65535 msec EP_C_ENABLE_RPM Engine rom must exceed EP_C_ENABLE_RPM before a switch fault can be detected Range 0 16
17. 0 Convert Commande 40 Convert EPS Cal iofest 41 Convert Cal Fileiofevt 41 Convert Cal File to Strategy ccecccececeeeeeeeeeeeeceeeeesaaeeeeneeeeeeesaeeeeaaeseenees 41 GalbratecMlept RERE EE E AN EE AE EEE AE EA EEES DEE ATE E 42 Change EPS CGalbration 42 Download Cal File to EPS o c cece cece cc ce ee eececeece sees eeueceeeeuseaueneeeeeenesaeanees 43 Compare EPS Cal to File Cal 45 Change APECS Password 46 APS Calibration Wizard ccc cceecc cece ceccceeeeeeeceseecesueeeeceseeeseauaaeeueeeeneeseneees 47 Monitor Men esc exces E seed siathoas cc ides deg Eege 48 Parameter EE 48 Parameter lot eeng Aere cates E E de d doeanethededubtacventuvindsduelder aus 49 Display e LCE 50 Control Strategy ceccccccccccessecseeeceeeeeeaeeeeaaeegeneeecaaesseaaesseneeseaeeesaaesseaaeenenees 51 Parameter Je tee eet ee EE 51 Configure Men 52 Configure Serial Port 52 ele RO EE 52 Help Ree 52 ABOUT AG KEE EE 52 WSerS MaANUAl EE 52 CHAPTER 5 SERVICE OPTIONS s0sssseseeeeeeeececeesseeeneeeeeeeeceesseneeeeesneneasans 53 Product Service Option 53 Replacement Exchange cccsccceeesecceeeeeseceeeeneneeeeesnenceeesneeaeeeenenseeeenenaes 53 Flat Rate ema teure REENEN A 54 Flat Rate REManufacture doorman Addisadeilis vei E a aa 54 Returning Equipment for Hepair 54 Packing a Gontrol cs scs cesi deeg erative a a ee 54 Return Authorization Number 55 Replacement Parts ege geg Aiea aise de Eed i EEN A 55 How to Contact
18. 383 8 rpm Specify 0 for those inputs that should not be dependent upon rpm Woodward 19 EPS 1000 Engine Equipment Protection System Manual SE 4051 EP_C_RUN_TIME Engine rpm must exceed EP_C_ENABLE_RPM for EP_C_RUN_TIME seconds before a switch fault can be detected Range 0 8191 9 sec EP_C TIME Duration that contacts must remain closed to detect a fault This delay will occur after any delay imposed by EP_C_ENABLE_RPM and EP_C_RUN_TIME Range 0 65535 msec SWITCH_CTRL This parameter is used to configure the three EP inputs Each input may be configured separately for switch to ground or switch to battery voltage It is a binary parameter consisting of three bits each of which may be set to 1 switch to battery voltage or 0 switch to ground When a channel is configured for switch to battery voltage a weak pullup resistor to battery voltage is enabled Any time one bit is changed all eight bits must be entered in the correct order The bits are assigned as follows B7 B6 B5 B3 B2 B1 BO B4 0 0 0 0 0 EP_C EP_B EP_A EP_C Configuration for Engine Equipment Protection C input 0 Switch to ground 1 Switch to battery voltage EP_B Configuration for Engine Equipment Protection B input 0 Switch to ground 1 Switch to battery voltage EP_A Configuration for Engine Equipment Protection A input 0 Switch to ground 1 Switch to battery voltage LOSS TIME If a valid eng
19. DELAY_1 0 no delay on reset RESET_SPEED_1 SET_DELAY_1 0 no delay on set SET_SPEED_1 1000 set speed is 1000 rom CHNL_2 CONFIG 00000011 go to set mode on EP A or EP B fault CHNL 2 OP_MODE 0 normal speed switch mode CHNL_2 RESET 1 auto reset RESET_DELAY_2 0 no delay on reset RESET_SPEED 2 1200 reset at 1200 rpm SET_DELAY_2 1000 1000 msec delay on set SET_SPEED_ 2 1400 set speed is 1400 rom CHNL 2 CONFIG 00010111 go to set on EP A B C or LOSS CHNL 2 Op MODE 1 reverse speed switch mode CHNL_3_ RESET 3 manual reset only RESET_DELAY_3 RESET_SPEED_3 SET_DELAY_3 0 no delay on set SET_SPEED_3 1800 set speed is 1800 rom PULSES _PER_REV 4 configure speed input for 128 teeth rev PULSES PER UPDATE 1 update speed calc every 128 teeth SPEED_TYPE 1 configure speed input for ignition EP_A_ENABLE_RPM 0 no rpm delay EP_A_RUN_TIME 0 no startup delay EP_A_TIME 50 50 msec delay for fault detection EP_B_ENABLE_RPM 0 no rpm delay ER BRUN TIME 0 no startup delay ER RB TIME 50 50 msec delay for fault detection Woodward 30 EPS 1000 Engine Equipment Protection System Manual SE 4051 EP_C_ENABLE_RPM 0 no rpm delay EP_C_RUN_TIME 0 no startup delay EP_C_TIME 50 50 msec delay for fault detection SWITCH_CTRL 00000000 configure all 3 EP inputs for switch to ground AUTOCRANK_CONFIG AUTOCRANK_CRANK TIME AUTOCRANK_DELAY_TIM E A
20. FFECT SPARK IGNMON REMOTE ANNUNCIATOR LIGHTS Connecting a Wire To connect a wire e Strip off approximately 0 25 6 mm of insulation from the wire e With a small screwdriver open the terminal hole on the side of the terminal block e Insert the wire in the terminal hole If desired more than one may be inserted e Screw the terminal hole closed Woodward 9 EPS 1000 Engine Equipment Protection System Manual SE 4051 Wiring Gauge Wire gauges should be appropriate for the currents carried and the distances spanned The EPS 1000 itself draws very little current less than 150 mA steady state but can handle up to 10 amps per channel through the relay contacts WIRE GAUGE FUNCTION CONNECTION 18 20 AWG 0 2 A max ass AX1 AX2 16 AWG less than 5 A Relay contacts CH 1 2 3 NO NC C 14 AWG less than 10 A max Relay contacts CH 1 2 3 NO NC C 2 conductor shielded cablet Speed sensor IN IN CAUTION Relay contacts are limited to 10 amps max Currents on the relay contacts greater than 10 amps can damage the circuit board If the load exceeds 10 A an appropriately sized interface relay should be used t Cable shielding must be connected to Ground GND Arc Suppression Circuits Inductive loads on relay contacts create an electromotive force during contact openings causing arcing to occur across the contacts This can significantly reduce contact life Ad
21. High SEQ_L Bit 5 Sequencing 0 Disable flag Low LOSS Loss Bit 4 of Speed 1 Enable Signal flag Start_SW Bit 3 Start switch 0 Disable enable EP_C Engine Bit 2 Protection 0 Disable Switch C CHANNEL 2 Se EP_B Engine Bit 1 Protection 0 Disable Switch B enable EP_A Engine Bit 0 Protection 0 Disable Switch A enable Standard relay logic CHNL 2 Channel 2 OP MODE operating mode CHNL_2_ Automatic RESET Reset mode 0 80 Time speed must be below RESET 0 65535 ms 0 0 ms SPEED 2 for reset to occur RESET_ DELAY 2 Woodward 24 EPS 1000 Engine Equipment Protection System Manual SE 4051 RESET_ SPEED 2 Reset speed 0 16383 8 rom 0 rpm SET_ DELAY 2 Time speed must be above SET_ SPEED_2 before the channel will go to the Set condition 0 65535 ms 0 ms SET_ SPEED 3 Speed set point in RPM 0 16383 8 rom 1 rpm CHANNEL 3 Woodward CHNL_3_ CONFIG Channel 3 configuration Bit 7 Bit 6 OS_EN Overspeed Enable flag GEO H Sequencing flag High Disable Disable Bit 5 SEQ_L Sequencing flag Low Disable Bit 4 LOSS Loss of Speed Signal flag Enable Bit 3 Bit 2 Start_SW Start switch enable EP_C Engine Protection Switch C enable Disable Disable Bit 1 EP_B Engine Protection Switch B enable Disable Bit 0 EP_A Engine
22. Replacement Exchange Replacement Exchange is a premium program designed for the user who is in need of immediate service It allows you to request and receive a like new replacement unit in minimum time usually within 24 hours of the request providing a suitable unit is available at the time of the request thereby minimizing costly downtime This is also a flat rate structured program and includes the full standard Woodward product warranty Woodward Product and Service Warranty 5 01 1205 This option allows you to call in the event of an unexpected outage or in advance of a scheduled outage to request a replacement control unit If the unit is available at the time of the call it can usually be shipped out within 24 hours You replace your field control unit with the like new replacement and return the field unit to the Woodward facility as explained below see Returning Equipment for Repair later in this chapter Charges for the Replacement Exchange service are based on a flat rate plus shipping expenses You are invoiced the flat rate replacement exchange charge plus a core charge at the time the replacement unit is shipped If the core field unit is returned to Woodward within 60 days Woodward will issue a credit for the core charge The core charge is the average difference between the flat rate replacement exchange charge and the current list price of a new unit Return Shipment Authorization Label To ensure prompt receip
23. SE 4051 W wooDWARD EPS 1000 Engine Equipment Protection System User s Manual Manual SE 4051 dd WARNING Read this entire manual and all other publications pertaining to the work to be performed before installing operating or servicing this equipment Practice all plant and safety instructions and precautions Failure to follow instructions can cause personal injury and or property damage The engine turbine or other type of prime mover should be equipped with an overspeed shutdown device to protect against runaway or damage to the prime mover with possible personal injury loss of life or property damage The overspeed shutdown device must be totally independent of the prime mover control system An overtemperature or overpressure shutdown device may also be needed for safety as appropriate CAUTION To prevent damage to a control system that uses an alternator or battery charging device make sure the charging device is turned off before disconnecting the battery from the system Electronic controls contain static sensitive parts Observe the following precautions to prevent damage to these parts e Discharge body static before handling the control with power to the control turned off contact a grounded surface and maintain contact while handling the control e Avoid all plastic vinyl and Styrofoam except antistatic versions around printed circuit boards e Do not touch the components or conductors on a
24. UTOCRANK_MAX_TRIES AUTOCRANK_DELAY_TIM E AUTOCRANK_MAX_TRIES AUTOCRANK_NS_ TIME AUTOCRANK_REST_TIME CRANK_DISABLE GLOWPLUG_TIME Example 2 AutoCrank Module with Glow Plug amp Overspeed Shutdown The EPS 1000 is to be connected to a diesel engine that senses engine speed from the flywheel with a magnetic pickup The flywheel has 128 teeth The three channels are to be configured as follows Channel 1 Glow plug controller Turn on for 30 seconds Channel 2 Autocrank controller Allow 10 second glow plug pre heat Crank for 10 seconds Rest for 15 seconds Permit up to 4 attempts before disabling Disable autocrank if any engine equipment protection faults exist Channel 3 Overspeed Protection Speed Switch reverse mode for fail safe Set speed of 2200 rpm with a 2 second delay Reset with manual switch only Go to set condition on EP A EP B EP C loss of speed signal or start switch off Engine Equipment Protection EP Channel A Water temperature switch switch to ground no rpm or time delay Woodward 31 EPS 1000 Engine Equipment Protection System Manual SE 4051 Channel B Water level switch switch to ground no rpm or time delay Channel C Oil pressure switch Disable until rom exceeds 1000 rpm for 5 Woodward seconds CHNL_1_CONFIG CHNL_1_OP_MODE 3 Glow plug mode CHNL
25. Woodward 0c0ccccsesseeeeeeeeeeeeseeeeseseeeeeeeseeeeeeeeeeeeeeeeeeeeeeeeeeees 55 Engineering Gervices iirin iinditan ii i iiaa 56 Technical Assistance EE 57 Woodward ii EPS 1000 Engine Equipment Protection System Manual SE 4051 Chapter 1 General Information SEH System Components The three main components of the system are 1 EPS 1000 controller module 2 EPS calibration tool kit ACT and 3 speed sensor if used in speed switch mode In addition and depending on the features selected several subcomponents such as oil pressure switches and temperature switches may be connected to the system EPS 1000 Controller The EPS 1000 is a programmable three channel equipment protection module designed to perform a variety of functions simultaneously It is suited for engine equipment protection sequenced operations and critical timing applications It can also be used for unattended engine starting using autocrank and glow plug functions The controller is software programmable and has no manual adjustments The All purpose Calibration Tool ACT is used for programming configuring and adjusting the EPS module Figure 1 EPS 1000 Module Calibration Tool Kit ACT The calibration tool kit includes an interface module RS 232 cable installation guide and the calibration software ACT CD ROM ACT is a PC personal computer based software calibrating and monitoring tool ACT is designed specificall
26. _1_ RESET RESET _DELAY_1 RESET_SPEED_1 CHNL_2 CONFIG CHNL 2 OP_MODE 2 Autocrank mode CHNL_2 RESET RESET DEL Ay 2 RESET SPEED 2 SET_DELAY_2 SET_SPEED 2 go to set on EP CHNL_3 CONFIG 10011111 oar GE 9r enable CHNL_3_OP_MODE 1 A ai CHNL_3_RESET 3 Haas SE HEGET D LAN 3 RESET_SPEED_ 3 SET_DELAY_3 BODE lt A second SE on set SET_SPEED_3 2200 set speed configure speed PULSES PER BEN 128 input for 128 teeth rev SPEED TYPE 0 W configure speed input for MPU EP_A_ENABLE_RPM 0 no rpm delay EP_A_RUN_TIME 0 no startup delay EP_A TIME Do EP_B_ENABLE_RPM 0 no rpm delay ER BRUN TIME 0 no startup delay 32 EPS 1000 Engine Equipment Protection System Manual SE 4051 Woodward 50 msec delay GE 3 for fault detection EP_C_ENABLE_RPM 1000 Sey until rpm gt 1000 EP_C_RUN_TIME 50 5 sec delay after 1000 rpm EP_C_TIME 50 50 msec delay for fault 200 msec delay EP_C_TIMEOUT 200 to detect loss at signal configure all 3 SWITCH_CTRL 00000000 EP inputs for switch to ground disable AUTOCRANK_CONFIG 00000111 autocrank for EP A B C AUTOCRANIE CRANK 10 0 crank for 10 sec TIME AUTOCRANK_DELAY_ 10 0 wait 10 seconds TIME i for glow plug heat AUTOCRANK_MAX_ 4 maximum of 4 TRIES crank attempts AUTOCRANK_NS_ TIME 1 5 Nea cab speed pulses rest time BOT OC RANE 15 0 between crank TIME attempts CRANK DISABLE 7507 crank EE rp
27. al generators may also be used See Speed Input Calibration section for further information e Front panel LED s provide instant visual data on operational status e Autocrank mode allows programming for crank time rest time and maximum crank attempts e Glow plug mode controls glow plug ON time e Test verify function permits testing of channel at 70 of set point pro grammable 0 to 99 of set point e Normal or reverse relay logic is configurable by user e Six switch inputs plus engine speed input provide versatile programming e Engine equipment protection EP switch inputs can be enabled at present programmable RPM after present time delay e Two auxiliary outputs indicate status and fault codes e Engine status indicator displays engine failure codes to aid in trouble shooting engine or equipment problems Woodward 2 EPS 1000 Engine Equipment Protection System Manual SE 4051 Specifications Electrical Power Input 9 30 Vdc Reverse Polarity Protection Electromechanical Compatibility SAE J1455 ISO 14982 1982 E EMI Immunity 30 V M 20 MHz to 1000 MHz Auxiliary Outputs AX 1 and AX 2 200 mA Nominal Operating Current Standby 12 V 140 mA 24 V 120 mA 12 V 25 mA 24 V 40 mA Relay Contact Ratings 28 Vdc Resistive Load 1 to 10A Inductive Load 1 to 8A Mechanical Operating Temperature Vibration Shock Housing 40 F to 185 F 40 C
28. and glow plug functions in response to engine equipment protection faults It is a binary parameter consisting of three bits each of which may be set to 1 enable or 0 disable Any time one bit is changed all eight bits must be entered in the correct order The bits are assigned as follows B7 B6 B5 B3 B2 B1 BO B4 0 0 0 0 0 EP_C EP_B EP_A EP_C Engine Equipment Protection Switch C enable When set to 1 autocrank and glow plug operation will be disabled in the event of a fault condition on EP switch C When set to 0 the channel ignores the status of the engine protect C fault Woodward 21 EPS 1000 Engine Equipment Protection System Manual SE 4051 EP_B Engine Equipment Protection Switch B enable When set to 1 autocrank and glow plug operation will be disabled in the event of a fault condition on EP switch B When set to 0 the channel ignores the status of the engine protect B fault EP_A Engine Equipment Protection Switch A enable When set to 1 autocrank and glow plug operation will be disabled in the event of a fault condition on EP switch A When set to 0 the channel ignores the status of the engine protect A fault AUTOCRANK_CRANK_TIME Specifies the maximum time in seconds that the engine will crank If the engine starts during the crank period engine cranking will be terminated Range 0 31 9 sec AUTOCRANK_DELAY_TIME Once the start switch has been turned on th
29. ated 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 Therefore the signal from the ignition will have one pulse per engine revolution PULSES_PER_REV 1 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 _PER_REV number of cylinders 2 PULSES PER REN 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_REV 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 rpm Therefore all set speeds 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 SPEED TYPE This parameter allows the user to optimize the input circuitry for the type of speed sensing devise being used 0 Magnetic Pickup MPU sometimes referred to as a variable reluctance sensor If using a Mini Gen signal generator configure it as
30. calibrate only those parameters you intend to change Woodward 47 EPS 1000 Engine Equipment Protection System Manual SE 4051 3 Press lt Enter gt to continue or lt Esc gt to abort the Wizard If you press lt Enter gt the Wizard will lead you through the calibration process with a series of questions When all questions have been answered the Wizard will ask you to confirm that the values entered are accurate 4 Press lt Enter gt to confirm the values lt PgUp gt to go back and change the values or lt Esc gt to abort the Wizard If you press lt Enter gt the EPS Wizard will download the new calibration and reset all EPS parameters This will complete the EPS Wizard operation NOTE The EPS Calibration Wizard only covers basic calibration It does not automatically assure optimum engine operation Please refer to EPS Wizard for more information Monitor Menu The Monitor Menu allows you to observe engine and EPS 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 The application will launch the view screen 2 To stop the updating click on Stop The button name will then change to
31. ceeecneeeeneeeeeeeeseaeeeeaaeeteaeeseeeeeseaeeesaeeseeeees 5 Set ys Resele EAR TS ERE 5 Normal vs Reverse Relay Logic sessseeesrresssrresesrneersnnesrrnneernnnnsrenneennnnnaee 5 le le CEET 6 KE ele EE 6 Indicator Lamps LED S siiicar naiaiae nanasa anaa iiaia aiian 6 Faull GOdES eera a EREA E EAEE NE RERE E ERATES 7 CHAPTER 2 WIRING INSTRUCTIONS c cccceccecsssssseeeeeeeceecnssseeeeeseseeneaseeess 8 Terminal Tee ET 8 Connection Diagram insseiirnireri iiaiai asa ania aa aa a iaa iae 9 Connecting a Wire csser naaca ias 9 Wiring Gage TEE 10 Arc Suppression Circuit 10 CHAPTER 3 CALIBRATING EPS FEATURES csecccesseeeeeeeeeseeeeeeesseneeeeeeees 11 Calibration Ee e E E E E A 11 Safety le TEE 11 Galibration C Ee 11 Calibrating an EPS UNIN EE 11 Saving a Calibration Set to File cceceeeeeseeeeeeeeseaeeeeeeeeseeeesaeeesaeesenees 12 Calibrating an EPS Unit with a Saved Calibration File 12 EPS ET TEE 13 Calibration Parameterg tt ntsttn rnnt tnnnsttnnnnttn anster annatta nnne nn nnmnnn nnee 13 Frequently Asked Questions cceeececeteeeeeeeeeneeeceaeeeeaaeseeneeceaeeesaaeseeneeeeaas 13 Channel Calbraiton esris keres inanan aaae RaR KARANE REER K EREEREER ANES RREK 14 speed Input Calibration TT 17 Questions about PDULGESG DER DEN 18 Engine Protection Calbratton 19 Autocrank A Glow Plug Calibration c cccccceeeseeeeeeeeceneeeecaeeseeeeeseaeeeseaeeneeeeeaes 21 All Calibration Parameiers rnnt tn nssr
32. ch mode Channel relay is energized in Set mode 1 Reverse Speed Switch operation Channel relay is energized in Reset mode 2 Autocrank mode Channel is enabled for autocrank operation Once the start switch is turned on contacts closed the channel will wait AUTOCRANK_ DELAY_TIME seconds before turning on the channel relay to allow for glow plug heat up if enabled The relay will remain on for AUTOCRANK_CRANK_TIME Woodward 15 EPS 1000 Engine Equipment Protection System Manual SE 4051 seconds then turn off for AUTOCRANK_REST_TIME seconds The sequence will be repeated up to AUTOCRANK_MAX_TRIES attempts before flagging an overcrank fault If the engine starts during any of the crank attempts the sequence will be stopped and the relay turned off See Autocrank and Glow Plug Calibration for further information 3 Glow Plug mode Channel is enabled for glow plug operation The relay will turn on for GLOW PLUG_TIME seconds after the start switch is turned on See Autocrank and Glow Plug Calibration for further information CHNL_X_RESET This parameter determines how the channel will respond once it enters the Set mode due to the engine speed exceeding the set speed The Reset mode is interpreted as follows 0 Auto80 The engine speed will return to Reset mode when the engine speed falls below 80 of SET_SPEED_X for RESET_DELAY_X msec 1 Auto The engine speed will return to Reset mode when the engine speed falls b
33. d per engine revolution See PULSES PER REV description below to determine that number according to your chosen speed signal The EPS 1000 speed input can be calibrated either through the Wizard or by selecting the command sequence Calibrate Change Calibration Speed Input Calibration Calibration Parameters Needing Configuration PULSES_PER_UPDATE The number of speed pulses over which the speed measurement is averaged The fewer the pulses the faster the update rate and the lower the resolution the greater the pulses the greater the averaging effect on calculated engine speed Factory setto zero Must be non zero to operate As a rule of thumb set PULSES PER UPDATE equal to PULSES_PER_REV Setting PULSES_PER_UPDATE to a lower value may speed response of the speed switch but it may also make the response more sensitive to instantaneous accelerations of the engine speed or variations in tooth spacing When working with very low speeds PULSES PER UPDATE may be reduced as low as 1 Range 0 255 NOTE When PULSES_PER_UPDATE equals zero the EPS 1000 will flag a fault code 7 User has not calibrated Speed Switch The EPS 1000 will not function with this fault PULSES PER_REV The number of speed pulses that will be generated per engine revolution Setting PULSES PER_REV to 60 will permit the operator to use units of Hz but may not work well at very low frequencies Range 0 32767 5 NOTE When PULSES PER UPDATE equals zero
34. d to viewing saving and converting files The following commands are available under the File Menu e Save EPS Cal to File e View Cal File Comments e View Text File e Convert EPS Cal to Text e Convert Cal File to Text e Convert Cal File to Strategy Save EPS Cal to File This command allows you to save EPS calibration data to a designated file The ACT uploads the calibration set from the EPS controller and saves it to a computer file This operation is usually done after the controller has been calibrated for satisfactory engine performance but can also be done at any other time The data is saved in a binary file format that is not readable To Save EPS Cal to File 1 Choose File gt Save EPS Cal to File ACT will prompt the path where the file will be saved 2 Enter a file name to 2x save the calibration Save in CQ ACT e ct em data to ACT will automatically append the file extension ACT to the file name if you do not specify one Click Save fiename baang or press lt Enter gt Save as type CAL Files ACT e Cancel A ACT will then read all of the current calibration values from the controller This screen shows the SSeS progress Processing Calibration Values SET_SPEED_4 Woodward 38 EPS 1000 Engine Equipment Protection System Manual SE 4051 Once all the values are read ACT will prompt you to add comments to the ACT file to aid in later identification Cn 4 2
35. d with each feature must be calibrated using the calibration tool ACT They can be set either individually or through use of the Wizard tool The four calibration categories are e Channel Calibration e Speed Input Calibration e Engine Protection Calibration e Autocrank amp Glow Plug Calibration Please refer to List of Parameters for a complete listing of all EPS parameters descriptions and factory settings Calibrating an EPS Unit Once the system set up is complete it is fairly easy to calibrate an EPS 1000 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 EPS controller unit 1 Ifan icon for the calibration tool exists double click on it to start the ACT software Woodward 11 EPS 1000 Engine Equipment Protection System Manual SE 4051 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 4 Follow the procedure outlined in the Configure Menu to change the COM port assignment if needed 5 If you wish to use the Wizard for basic calibration refer to EPS Calibration Wizard The Wizard is an interactive guide to help you get your controller running as quickly as possible 6 Beyond basic calibration there are many para
36. ding an arc suppression circuit will increase contact life in those applications The following are examples of circuits that will protect contacts from inductive load induced arcing OH Ka Ki gend w gt 5 e Figure 4 Varistor Circuit Figure 5 Diode Circuit Woodward 10 EPS 1000 Engine Equipment Protection System Manual SE 4051 Chapter 3 Calibrating EPS Features BEE Calibration Guide This section explains the procedures for calibrating configuring and adjusting the various EPS 1000 features to work with your application Before proceeding make sure you have completed the installation of all the required hardware for your system and are familiar with using the All purpose Calibration Tool ACT Safety Precautions The EPS 1000 is a user configurable engine control device and will follow your settings and commands immediately Please be aware of this when calibrating and entering values in the unit It is possible to enter values in the EPS unit that are in excess of what the engine is capable of performing and outside of safe operating range It is the user s responsibility to be accurate when entering data into the EPS or the ACT Entering values outside of safe operating range can result in serious physical injury and or damage to the equipment or application Calibration Categories To incorporate any of the programmable features in your system a set of parameters associate
37. do we need to calibrate the EPS system EPS 1000 is a software programmable system and has no manual adjustment Calibrating is the only means of configuring the controller for your specific application Do I 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 zero and must be calibrated to a non zero value before normal EPS operation can begin It is recommended that you review all settings for your own application Is it possible to enter values in EPS 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 There are certain parameters that are used to properly configure an application Entering incorrect values for these parameters will result in improper configuration and may permit the engine to run at maximum throttle Entering values outside of safe operating range can result in serious physical injury and or damage to the equipment Channel Calibration Please Note In the following calibration instructions X represents the channel number for calibration Always replace X with either 1 2 or 3 The channel number you choose will be consistent throughout the instruction Channel X can be calibrated eithe
38. e autocrank logic will wait AUTOCRANK_DELAY_TIME seconds before beginning the crank sequence Range 0 8191 9 sec AUTOCRANK_MAX_TRIES Maximum number of crank rest cycles before autocrank logic stops trying to start the engine and flags a fault Range 0 255 AUTOCRANK_NS_TIME The maximum time after onset of cranking the logic will wait to detect an engine speed If engine speed is not detected during this time the autocrank logic will terminate cranking will be disabled and a fault code will be set This feature may be disabled by setting AUTOCRANK_NS_TIME longer than AUTOCRANK CRANK_TIME Range 0 31 9 sec AUTOCRANK_REST_TIME If the engine does not start during the cranking interval cranking will be disabled for AUTOCRANK_REST_TIME seconds in order to permit the starter motor to cool Range 0 31 9 sec CRANK_DISABLE The engine rpm that must be exceeded to terminate the autocrank logic Range 0 16383 8 rpm GLOWPLUG_TIME Once the start switch has been turned on the glow plug logic will turn on the output for GLOW PLUG_TIME seconds before beginning turning off Range 0 8191 9 sec All Calibration Parameters The All Parameters option under Calibrate Change EPS calibration allows the user to access all calibration parameters including some that are not available from the other windows The parameters are presented in alphabetical order Most of the parameters appear under other headings e g Channel 1 Calibration S
39. ecord of the file compare You will then be asked to select a destination directory and file name Change APECS Password This command allows you to add or change a password to protect certain calibration features The option is useful for example to prevent unauthorized changes to a known good calibration set in the EPS unit By default the EPS unit is not password protected To Change EPS Password 1 Choose Calibrate gt Ee xi Change EPS Pass GE Ge dee E Please enter the controller password Se rent password change _ Cem JH Status Enter password and click OK Password Management ES 2 The application will query the controller to verify that the ente ail p asswo rd Please enter the controller password matches the current password If the passwo rd matches eae Change Cancel the Chan ge button Password Valid Click Change to change controller password is enabled Woodward 46 EPS 1000 Engine Equipment Protection System Manual SE 4051 3 Click Change and the application will prompt for the new password 4 Enter the new password Password Management x It should be one word no spaces and up to 11 Enter new Password characters long Once en tered click OK The appli cation will prompt to m Cancel ox reenter the password to Password Deche make sure that it was typed in properly 5 Re enter the password x and click OK If the two entries of the
40. ed for satisfactory EPS operation with another EPS unit To Download a Cal File to APECS 1 Choose Calibrate gt Download Cal File to APECS The following screen allows you to select a Cal file to download e ene zo Filename J Open Files of type Cal Files 000 ACT Z Geet Cancel I Open as read only Calibration File Comments 2 Choose a file and click OK The following screen will show the progress Processing Calibration Values OVERSPEED_RPM 3 The following screen is shown when the operation is complete ACT x A The calibration file was downloaded successfully Woodward 43 EPS 1000 Engine Equipment Protection System Manual SE 4051 NOTE Gi 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 To Download a Cal File to APECS with a Password Different from that of the APECS Unit Whenever the EPS 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 EPS operation if the password stored in the calibration file matches the password in the unit ACT will readily download the calibration to the EPS unit However if the password stored in the calibration file does
41. elow RESET_SPEED_X for RESET_DELAY_X msec 2 Latch The channel will remain latched in Set mode until power to the EPS 1000 module is cycled off and on 3 Manual The channel will remain in Set mode until the manual reset switch is pressed or the power to the EPS module is cycled off and on RESET DELAY X When Channel X is configured for Auto80 or Auto Reset mode this parameter determines how long in milliseconds the engine speed must be below RESET _ SPEED_X before the channel will return to the Reset condition Range 0 65535 msec RESET_SPEED_X When Channel X is configured for Auto Reset mode this parameter determines the rpm that engine speed must fall to return to the Reset condition Reset speed must be set below set speed Range 0 16383 8 rpm 0 is a valid value SET_DELAY_X This parameter determines how long in milliseconds the engine speed must be above SET_SPEED_X before the channel will go to the Set condition Range 0 65535 msec SET_SPEED_X When Channel X is configured as a speed switch this parameter determines the rpm that engine speed must exceed for the channel to go to the Set condition Range 0 16383 8 rpm Woodward 16 EPS 1000 Engine Equipment Protection System Manual SE 4051 Speed Input Calibration The EPS 1000 interprets all speeds in terms of RPM rather than Hz In order to properly interpret the speed signal it is necessary to specify the number of speed pulses that will be generate
42. figurations by changing the configuration on the parameter list screen F9 or Open then opening a new Parameter View NOTE Only one of the parameter view screens can be monitoring the controller at once Woodward 51 EPS 1000 Engine Equipment Protection System Manual SE 4051 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 EPS controller To Configure the Serial Port 1 From the main menu screen Serial Port The application will Serial Controller Connection display the following screen C Com St Cancel C Com2 C APECS 500 2 Choose a port and Click OK peen PEPE This screen will be displayed DPE on application startup if a SERED controller cannot be found at SEL the last selected port and can be changed any time after the application has started 3 Select Custom port if you are using COM 3 or COM 4 4 Select EPS 1000 Demo to run a demonstration of the software Help Menu The Help Menu provides access to the online user s manual and other helpful information helpful The following are available under the Help Menu e Help Topics e About ACT e Users 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
43. for Channel 3 if this bit is set to 1 Channel 2 must be in a Set state before enabling Channel 3 to look for a set condition When set to 0 the sequencing function is disabled SEQ_L Sequencing flag Low When set to 1 the lower of the remaining channels must have exceeded its set speed before enabling this channel e g for Channel 1 if this bit is set to 1 Channel 2 must be in a Set state before enabling Channel 1 to look for a set condition for Channel 2 if this bit is set to 1 Channel 1 must be in a Set state before enabling Channel 2 to look for a set condition for Channel 3 if this bit is set to 1 Channel 1 must be in a Set state before enabling Channel 3 to look for a set condition When set to 0 the sequencing function is disabled LOSS Loss of Speed Signal flag When set to 1 the channel will go to a set condition if a valid speed signal is not observed within LOSS_TIME seconds of the start switch going to the On state or if the engine speed drops from a running speed to zero When set to 0 the LOSS function is disabled Start_SW Start Switch enable When set to 1 putting the start switch in the Off condition contacts open will put Channel X in the Set condition regardless of the speed Returning the switch to the On condition will return the channel to the reset condition unless the Channel_X_reset parameter is configured for a latched reset mode When set to 0 the channel ignores the status of t
44. he start switch EP_C Engine Equipment Protection Switch C enable When set to 1 the channel will go to the Set condition in the event of a fault condition on engine equipment protection switch C The channel may return to a Reset condition if the fault no longer exists and the manual reset switch is cycled unless the Channel_X_reset parameter is configured for a latched reset mode When set to 0 the channel ignores the status of the engine protect C fault EP_B Engine Equipment Protection Switch B enable When set to 1 the channel will go to the Set condition in the event of a fault condition on engine equipment protection switch B The channel may return to a Reset condition if the fault no longer exists and the manual reset switch is cycled unless the Channel_X_reset parameter is configured for a latched reset mode When set to 0 the channel ignores the status of the engine protect B fault EP A Engine Equipment Protection Switch A enable When set to 1 the channel will go to the Set condition in the event of a fault condition on engine equipment protection switch A The channel may return to a Reset condition if the fault no longer exists and the manual reset switch is cycled unless the Channel_X_reset parameter is configured for a latched reset mode When set to 0 the channel ignores the status of the engine protect A fault CHNL_X_OP_MODE This parameter determines the operating mode of Channel X as follows 0 Normal Speed Swit
45. ill wait AUTOCRANK_DELAY_TIME seconds before turning on to allow for glow plug heat up if enabled The relay will remain on for AUTOCRANK CRANK_TIME seconds then turn off for AUTOCRANK_REST_TIME seconds The sequence will be repeated up to AUTOCRANK_MAX_TRIES attempts before flagging an overcrank fault If the engine starts during any of the crank attempts the sequence will be stopped and the relay turned off Anytime that cranking is enabled an engine rpm must be observed before AUTOCRANK_NS_ TIME seconds otherwise cranking will be aborted and a fault flagged Glow Plug The relay will turn on for GLOWPLUG_TIME seconds after the start switch is turned on The glow plugs can be configured to remain on even after engine starting The glow plug logic is not affected by engine rpm Even though there are three speed switch channels and any one or all three can be configured for autocrank or glow plug operation there is only one engine speed input For this reason there is only one set of calibration parameters for the autocrank and glow plug logic All three channels share the same autocrank and glow plug logic If more than one channel is configured for autocrank the relays will respond simultaneously Similarly H more than one channel is configured for glow plug operation the relays will respond simultaneously Calibration Parameters Needing Configuration AUTOCRANK_CONFIG This parameter is used to selectively disable the autocrank
46. ine speed is not seen within LOSS_TIME seconds of the start switch turning on a Loss of Speed Signal LOSS fault will be generated if any of the channels are configured for LOSS LOSS_TIME is enabled by setting Bit 4 of CHNL_X_CONFIG If autocrank and glow plug timer modes are used the LOSS_TIME should be adjusted to accommodate AUTOCRANK_DELAY_TIME In the case where runaway condition is a concern the LOSS_ TIME must be at a minimum and if a start switch is not used the start switch input must be connected to the Vbat SW_OPTIONS1 An 8 bit field of flags Only the least significant bit is used If the bit 1 engine speed data is interpreted without noise rejection If the bit 0 noise rejection is used see EPS _FIXED_DEADBAND Use a value of 1 for mag pickup or Hall Effect type inputs where the frequency is fairly high and a value of 0 for ignition Woodward 20 EPS 1000 Engine Equipment Protection System Manual SE 4051 type inputs Because the noise rejection logic imposes an execution time penalty it is best not to use it at high frequencies The value is automatically assigned by EPS Wizard TEST_VERIFY_K Specifies the multiplier to be used on the set speeds when the test verify switch has been activated Test verify affects all three set speeds Range 0 1 Nominal value is 0 7 30 reduction Autocrank amp Glow Plug Calibration Autocrank Once the start switch is turned on contacts closed the autocrank logic w
47. it failed EEPROM 14 No_factory_cal_fault 15 Switch input fault during EOL testing Woodward 7 EPS 1000 Engine Equipment Protection System Manual SE 4051 Chapter 2 Wiring Instructions Terminal Functions The 21 terminals and their functions are TERMINAL FUNCTION IN Speed Input IN Speed Input EPA Engine Equipment Protection Switch A EPB Engine Equipment Protection Switch B EPC Engine Equipment Protection Switch C STT Start Run Switch RST Manual Reset Switch VER Test Verify Switch AX1 Auxiliary Output 1 AX2 Auxiliary Output 2 GND Ground BAT Battery Positive 9 30 Vdc CH1 NO Channel 1 Relay Normally Open CH1 NC Channel 1 Relay Normally Closed CH1 C Channel 1 Relay Common CH2 NO Channel 2 Relay Normally Open CH2 NC Channel 2 Relay Normally Closed CH2 C Channel 2 Relay Common CH3 NO Channel 3 Relay Normally Open CH3 NC Channel 3 Relay Normally Closed CH3 C Channel 3 Relay Common Woodward 8 EPS 1000 Engine Equipment Protection System Manual SE 4051 Connection Diagram EPS 1000 ALTERNATIVE WIRING IN CH3C J Dhi ee CH3 NC ener _ ENGINE PROTECTION INPUT A CH3 NO cHanc CHE ee ______ _ ENGINE PROTECTION B CH2NO CH1NC ih _ ENGINE PROTECTION C CH1 NO Ti mv p dt fles i To BATTERY d SPEED SENSOR MAGNETIC PICKS HALL E
48. j Do you wish to edit the new Cal File Comments 3 If you click Yes the comment editor screen will appear To enter comments type them one at a time and press lt Enter gt or click Save Edit You can re edit comments by clicking them changing the text on the top line and clicking Save Edit Comments can be deleted by clicking on them and then clicking Delete or by pressing lt Del gt Cafi Mane ESA Comme Ut f Ss el 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 ACT x gt A C Woodward ACT Tool Cal tool stuff 1 ACT Created Successfully The file name in this message is the file selected in Step 2 ACT will save the calibration data to the designated file and display Calibration Data Saved in File ABCD ACT message where ABCD is the name you entered in Step 2 NOTE The Save 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 EPS Cal to Text and Convert Cal File to Text commands Woodward 39 EPS 1000 Engine Equipment Protection System Manual SE 4051 View Cal File Comments
49. m GLOW PLUG_TIME 30 0 aa glow plug time 33 EPS 1000 Engine Equipment Protection System Manual SE 4051 Chapter 4 Calibration Tutorial Se ACT Installation ACT Kit Contents ACT All purpose Calibration Tool is used for programming configuring and adjusting and monitoring the EPS controller with your personal computer The ACT kit contains the following e Software CD ROM e Interface module e RS 232 connecting cable e SE 4021 Installation amp Wiring 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 SGVA 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 EPS 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 EPS unit is off when making connections 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 EPS unit via the co
50. meters associated with EPS that can help enhance the performance of your equipment Read Calibration Parameters and decide on the parameters you would like to adjust 7 Access Change EPS Calibration option from the Calibrate Menu and select the desired parameter from the appropriate category Adjust the value of the parameter as needed 8 Repeat Step 5 until all desired parameters have been adjusted and satisfactory performance has been achieved Saving a Calibration Set to File After satisfactory 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 EPS units To Save a Calibration Set to File 1 Access the File Menu to activate the Save EPS Cal to File command 2 Enter a file name to save the calibration data to a designated file 3 When prompted to edit the comment list enter information that will help you keep track of specific engine 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 EPS Unit with a Saved Calibration File You may wish to calibrate additional EPS units with a saved calibration file for consistent optimized operation To Calibrate an
51. n e 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 A CAUTION To prevent damage to electronic components caused by improper handling read and observe the precautions in Woodward manual 82715 Guide for Handling and Protection of Electronic Controls Printed Circuit Boards and Modules Packing a Control Use the following materials when returning a complete control protective caps on any connectors e antistatic protective bags on all electronic modules e packing materials that will not damage the surface of the unit e atleast 100 mm 4 inches of tightly packed industry approved packing material a packing carton with double walls e astrong tape around the outside of the carton for increased strength Woodward 54 EPS 1000 Engine Equipment Protection System Manual SE 4051 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 ca
52. n be started until a purchase order is received NOTE We highly recommend that you make arrangement in advance for return shipments Contact a Woodward customer service representative at 1 800 523 2831 in North America or 1 970 482 5811 for instructions and for a Return Authorization Number Replacement Parts When ordering replacement parts for controls include the following information e the part number s XXXX XXXX that is on the enclosure nameplate e the unit serial number which is also on the nameplate How to Contact Woodward In North America use the following address when shipping or corresponding Woodward Governor Company PO Box 1519 1000 East Drake Rd Fort Collins CO 80522 1519 USA Telephone 1 970 482 5811 24 hours a day Toll free Phone in North America 1 800 523 2831 Fax 1 970 498 3058 For assistance outside North America call one of the following international Woodward facilities to obtain the address and phone number of the facility nearest your location where you will be able to get information and service Facility Phone Number Brazil 55 19 3708 4800 India 91 129 230 7111 Japan 81 476 93 4661 The Netherlands 31 23 5661111 You can also contact the Woodward Customer Service Department or consult our worldwide directory on Woodward s website www woodward com for the name of your nearest Woodward distributor or service facility For worldwide directory information go t
53. nctionality for this screen All of the data will be recorded in a revolving buffer for use by the Save to File feature see below The axis scales parameter names update resolution and time scale on the Parameter Plot may be changed as described in the Plot Setup screen To Change Plot Setup This allows you to choose engine rpm desired engine speed duty cycle or any other parameter for viewing real time plots on screen Axis scales can also be adjusted to fit the parameter and or speed 1 On the Parameter Plot screen click on Configure The application will show the following screen with the current values LE E Plot 2 spi mode zl rdes_sw_new E Axis Max 10 Axis Max 5 Axis Min D Axis Min 1 X Axis Time Scale 50 sec X Axis Sample Rate 100 msec 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 Woodward 49 EPS 1000 Engine Equipment Protection System Manual SE 4051 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 OK will save this information in the Windows Registry so that it will be remembered the next time the program is started NOTE The Calib
54. ne speed AUTOCRA NK_ d DEST Rest time 0 31 9 sec 15 15 sec TIME Crank GE disconnect 016999 8 700 700 rpm DISABLE rpm set point GLOWPLU G er 0 8191 9 sec 10 10 sec TIME 28 EPS 1000 Engine Equipment Protection System Manual SE 4051 Sample Applications The following are two sample applications with instructions for how to set the calibration parameters Example 1 Three Channel Speed Switch Spark Ignition Engine The EPS 1000 is to be connected to an eight cylinder spark ignition engine that senses engine speed from the ignition There will be one pulse per combustion event The three channels are to be configured as follows Channel 1 Speed Switch with set speed of 1000 rpm no delay Reset at 80 of set speed Go to set condition on EP A fault Channel 2 Speed Switch with set speed of 1400 rpm 1 second delay Reset at 1200 rom Go to set condition on EP A and EP B fault Channel 3 Speed Switch reverse mode Set speed of 1800 rpm Reset with manual switch only Go to set condition on EP A EP B EP C or loss of speed signal Engine Equipment Protection EP All three channels configured for switch to ground no enable speed or time delay Woodward 29 EPS 1000 Engine Equipment Protection System Manual SE 4051 CHNL_1_CONFIG 00000001 go to set mode on EP A fault CHNL_1_OP_MODE 0 normal speed switch mode CHNL_1_RESET 0 auto80 reset RESET _
55. new pass oo RR word are equal the new password will be encod ed and saved in the con GEN Change Cancel troller Password Change Mod 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 EPS 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 the password protected features APS 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 Calibrate a Controller Unit Using the EPS Calibration Wizard 1 From the main menu press lt C gt to open the Calibrate menu 2 Arrow down to Calibration Wizard and press lt Enter gt The Wizard will inform you if the unit has been previously calibrated or not NOTE 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
56. nnector on the harness Woodward 34 EPS 1000 Engine Equipment Protection System Manual SE 4051 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 Close all applications to prevent possible conflict between the ACT installer and other programs 1 Turn on your computer and insert the ACT disk into the CD ROM drive The install program should automatically launch If it does not open Windows Explorer go to the CD ROM drive and double click on the 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 the section below e Put the original CD ROM in a safe place in case the files on your hard drive are damaged or lost Basic ACT Operation Running the ACT Software The ACT software is fairly easy to use Follow the procedures below to run the program 1 Make certain that the EPS controller is powered up and connected to the computer s COM port x 2 Ifan icon for the Calibration ey Zoos ine Tool exists double click on This andthe accompa witen mae copie S is jare may e copied in wi
57. nnn nnne nn nnnn nanna 22 List of Parameters aessiiiiraone kaanane kaain RKRN KAKAA RANNA ARKATRA RKRN AKA KARRANKA ARREA REKK KRNS 23 Sample Applicaton S evs zsccecectecs deececauaces ees sadeveuiateveeenaeectivived aaa eaa aa a 29 Example 1 Three Channel Speed Switch Spark Ignition Engine 29 Example 2 AutoCrank Module with Glow Plug amp Overspeed Shutdown 31 CHAPTER A CALIBRATION TUTORIAL cccseeccceeeeeeeeeeeeeeeeeeseneeeeeeeseeeeneeeeees 34 AGT Installation EE 34 AGT Kit COMIGMIS vayesvis cuesciees desnietindeis thea rea ae ienie REENA RENEA EEEE 34 Set up Heouirements nese net ner nsinstnstnntnnsennsennstnnsennnsennsennnens 34 Hardware ett geg zesesdgedegiet e iian n Aa eia i aaan 34 Software GetUp cecccccccecececeeececeseeeesaeeeeaeeeeeeeeeeaaeseeaaeseeeeeseaeeeeaeseeaeessenees 35 Basic ACT Operation 35 Running the ACT Software seesseesseessiessrrssenrstnnsrnnstnnstnnstnnnnrnstrnnstnnenn nent 35 Progress Display Green 36 Woodward i EPS 1000 Engine Equipment Protection System Manual SE 4051 Moving Around the Software cccccccceeeeseeceeeeeeceeeeeeaeeeeneeseeeesaeesenaeeseaees 36 ACT Menus amp Options cee eeeeaeeeeaeeseeeeeceaeseeaaeseeeescaeeesaeeeeaeeeeaas 37 ACT Menus Structure 0 0 ccccccceececccccscsseeeeececeesesseaueeeeeeeeusaueeseseeeeeeeaneneess 37 Eleng ege ee e EE EE 38 Save EbGCaltotle ccc EEEE EE P E 38 View Cal File Comments 40 View Text File AE E E AE EE E E E 4
58. o www woodward comi ic locations Woodward 55 EPS 1000 Engine Equipment Protection System Manual SE 4051 Engineering Services Woodward Industrial Controls Engineering Services offers the following after sales support for Woodward products For these services you can contact us by telephone by email or through the Woodward website e Technical Support e Product Training e Held 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
59. onfigure and adjust various parameters associated with the EPS controller 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 A complete list of parameters appears at the end of this chapter All adjustments are stored immediately in non volatile memory in the EPS unit The EPS controller will retain the changes even if power is lost or the ACT is disconnected To Change EPS Calibration Parameters 1 Choose Calibrate gt Change EPS 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 Woodward 42 EPS 1000 Engine Equipment Protection System Manual SE 4051 Download Cal File to EPS The Download Cal File to EPS command allows you to download the entire calibration set from a file to the EPS permanent memory This is a convenient one step method for e Reverting back to a known good calibration set after experimenting with new calibration settings e Programming multiple EPS units for a particular application The downloaded file may have been previously configured and calibrat
60. or pail it to start the ACT software regardless ofthe fom of media wihovt pior The license screen will be Waa Ine makes aman tes displayed when the ACT is Peed ides yep mg au nch ed D Yo u m ust e ith e r Any damages loss of property of other costs resulting from the use of this software is the sole responsiblity accept th e te rms or Ca ncel of the individual or organization using which exits the application IT T accepi the tems of this agieement 3 If no icon exists click on Gei the Start button highlight Programs find the ACT software and click to start it Default is Woodward then select EPS Calibration Tool 4 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 Woodward 35 EPS 1000 Engine Equipment Protection System Manual SE 4051 Progress Display Screen This screen is intended to inform the user of the progress of time consuming communication procedures It will close automatically when the procedure is complete 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 e Use mouse to select or move around
61. peed Input Calibration but there are a number of lesser used parameters that do not Woodward 22 EPS 1000 Engine Equipment Protection System Manual SE 4051 List of Parameters CHANNEL 1 CHNL_1_ CONFIG Bit 7 Channel 1 configuration OS_EN Overspeed Enable flag Disable Bit 6 GEO H Sequencing flag High Disable Bit 5 SEQ_L Sequencing flag Low Disable Bit 4 LOSS Loss of Speed Signal flag Enable Bit 3 Start_SW Start switch enable Disable Bit 2 EP_C Engine Protection Switch C enable Disable Bit 1 EP_B Engine Protection Switch B enable Disable Bit 0 EP_A Engine Protection Switch A enable Disable CHNL_1_ OP_MODE Channel 1 operating mode Standard relay logic CHNL_1_ RESET Reset mode Automatic 80 RESET_ DELAY_1 Time speed must be below RESET SPEED_1_ for reset to occur 0 65535 ms RESET_ SPEED_1 Reset speed 0 16383 8 rom 0 rpm Woodward 23 EPS 1000 Engine Equipment Protection System Manual SE 4051 Time speed must be above SET_ GET SPEED_1 DELAY_1 before the channel will go to the Set condition 0 65535 ms 0 0 ms SET_ Speed set SPEED_1 point in RPM EE 1 1 rpm CHNL 23 Channel 2 CONFIG configuration OS_EN Bit 7 Overspeed 0 Disable Enable flag SEQ_H Bit 6 Sequencing 0 Disable flag
62. played on the Parameter View display To Display the Parameter List 1 Choose Monitor gt Parameter List from the main menu 2 The F5 F6 keys will backup advance through the list Press F9 or click on On View List to toggle the selected parameter on the Parameter View screen 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 nfo om Tvpein a file name that reflects the purpose of alana the saved configuration and click Save The view configuration dialog will now display the selected file name in the title bar Open Clicking Open will prompt the user for a file name of a previously saved View Configuration Fie name aeng Save ACT View Setup Fies art H Concel Select the desired file and click Open The View Configuration will be updated with the saved parameters The ACT application will always recall the default set of plot configuration parameters at application startup and does not recall the last used view setup file So the view configuration will always start with the default view Several parameter view screens can be open with different con
63. r through the Wizard or by going to the Calibrate Menu and selecting Change EPS Calibration Calibration Parameters Needing Configuration CHNL_X_CONFIG This parameter is used to determine how the channel will respond to the various switch inputs It is a binary parameter consisting of eight bits each of which may be set to 1 enable or 0 disable Any time one bit is changed all eight bits must be entered in the correct order The bits are assigned as follows B7 B6 B5 B4 B3 B2 B1 BO OS EN SEQ_H SEQ L LOSS Start GW EP_C EP_B EP_A OS_EN Overspeed Enable flag When set to 1 a fault code will be generated any time Channel X goes to a set condition due to the engine speed exceeding set_speed_X The fault code will be flashed on the engine status lamp The overspeed fault will remain latched until power up or manual reset even if the channel is set for automatic reset Enable if Channel X used for overspeed protection SEQ_H Sequencing flag High When set to 1 the higher of the remaining channels must have exceeded its set speed before enabling this channel e g for Channel 1 if this bit is set to 1 Channel 3 must be in a Set state before enabling Woodward 14 EPS 1000 Engine Equipment Protection System Manual SE 4051 Channel 1 to look for a set condition for Channel 2 if this bit is set to 1 Channel 3 must be in a Set state before enabling Channel 2 to look for a set condition
64. ration 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 1 Choose Monitor gt Display Faults from the main menu The application will launch the Fault view The application will update the display every time the controller sends the fault_flags status This happens several times a second 2 Click on the Pause a button to stop the EE RE automatic update of this screen The text on the button will change to Start and clicking it again will re start the automatic updating NOTE If any other screen requests data from the controller while this screen is updating this screen will automatically Pause Woodward 50 EPS 1000 Engine Equipment Protection System Manual SE 4051 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 dis
65. s energized e When a channel is configured as a glow plug controller its LED will be illuminated when the relay is energized glow plug ON e When a channel is configured as an autocrank controller its LED will be illuminated when the relay is energized The LED will flash rapidly during the starter rest period relay de energized Woodward 6 EPS 1000 Engine Equipment Protection System Manual SE 4051 Fault Codes The EPS 1000 is capable of detecting a variety of fault conditions When one is detected the green Status LED will flash a fault code that is indicative of the fault detected This permits identification of fault conditions without the need for a service tool If multiple faults are detected simultaneously only the highest priority fault lowest code number will be flashed Count the flashes to determine the fault condition being expressed The following table lists the faults and their respective flash codes FLASH FAULT CONDITON CODE 1 Channel 1 Overspeed 2 Channel 2 Overspeed 3 Channel 3 Overspeed 4 Engine Equipment Protection Switch A fault 5 Engine Equipment Protection Switch B fault 6 Engine Equipment Protection Switch C fault 7 Loss of speed signal fault 8 Autocrank unable to start engine 9 User has not calibrated EPS 1000 10 Auxiliary Output 1 Over current fault 11 Auxiliary Output 2 Over current fault 12 TXD Output Over current fault 13 Speed switch un
66. s is as follows 1 In Convert EPS Cal to Text operation the calibration set that is converted is from the EPS unit 2 In Convert Cal File to Text operation the calibration set that is converted is from a previously saved file You may use the View Text File command to view text files Woodward 40 EPS 1000 Engine Equipment Protection System Manual SE 4051 Convert EPS 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 EPS Calibration to Text Choose File gt Convert EPS 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 1 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
67. t of the core and avoid additional charges the package must be properly marked A return authorization label is included with every Replacement Exchange unit that leaves Woodward The core should be repackaged and the return authorization label affixed to the outside of the package Without the authorization label receipt of the returned core could be delayed and cause additional charges to be applied Woodward 53 EPS 1000 Engine Equipment Protection System Manual SE 4051 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 informatio
68. the menu e Use left mouse to execute a command or accept a condition e Use function key lt F1 gt for HELP e AHOT key highlighted character in a menu item can also be used to access or activate a menu or sub menu e g File use lt ALT gt lt F gt e Click on the x box in the upper right hand corner to exit ACT Woodward 36 EPS 1000 Engine Equipment Protection System Manual SE 4051 ACT Menus amp Options ACT Menus Structure 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 MAIN MENU COMMANDS Save EPS Cal to File View CAL File Comments View Text File FILE MENU Convert EPS Cal to Text Convert Cal File to Text Convert Cal File to Strategy Change EPS Calibration Download Cal FILE to EPS CALIBRATE MENU Compare EPS Cal to File Change EPS Password Calibration Wizard Parameter View Parameter Plot MONITOR MENU Display Faults Control Strategy Parameter List COM 1 COM 2 CONFIGURE MENU Custom Serial Port EPS 1000 Demo APECS Demo Modes Help Topics HELP MENU About ACT User Manuals Woodward 37 EPS 1000 Engine Equipment Protection System Manual SE 4051 File Menu The File Menu allows you to perform operations relate
69. to 85 C 4 G s from 40 to 2000 Hz 10 G s 45 Hz UV chemical resistant UL 94 V O flame retardant Encapsulated for reliability in harsh environments Terminations Euro style terminal block Requires interface adapter and Calibration software EPS Calibration Tool Kit SA 4479 Weight 0 85 Ibs 0 386 kg Woodward EPS 1000 Engine Equipment Protection System Manual SE 4051 Dimensions amp Mounting Select standard 10 screws of suitable length and thread type to ensure proper mounting SCREWS TO SECURE ASSEMBLED ENCLOSURE TO PANEL SNAP LEDGE TO SECURE CASE TO FRAME Module Dimensions 5 21 L x 3 88 W x 1 44 D 132 3 mm L x 98 5 mm W x 36mm D Reversible Frame The EPS 1000 s unique patented enclosure accommodates either panel or base mounting Case e Allows for unobtrusive access to terminal block for ease of wiring e Terminal descriptions identified above connections on side of case e LED s and engine failure codes prominently displayed on front panel e Snap ledges secure case to frame e Panel Mount When attached to top of case module can be installed below a surface in a cutout measuring 5 25 L x 4 W 133 5 mm x 101 6 mm e Base Mount When attached to bottom of case module can be mounted above a surface Built in aperture allows convenient exit for wires and or connections Woodward 4 EPS 1000 Engine Equipment Protection System
70. to be configured for autocrank the Wizard will ask questions regarding the number of crank cycles crank time rest time etc Lastly if the channel is to be configured as a glow plug controller the Wizard will request the glow plug time In order to streamline the process only those questions needed are asked For example if a channel is to be configured for autocrank it is not necessary to enter set and reset criteria Similarly if the channel is to be configured as a speed switch autocrank and glow plug information are not requested Lastly the Wizard requests information regarding desired configuration of the three engine equipment protection EP switches Online help with Wizard context is readily available through the Help Menu or in some instances by placing the cursor over the item in question Before downloading the new calibration data to the EPS 1000 the Wizard presents a brief summary of the new configuration for final approval Calibration Parameters Frequently Asked Questions What is a calibration parameter A parameter is a numerical value that helps the calibrator adjust or set the EPS controller Once fixed by a calibrator the parameter is not subject to change while the system is operating EPS calibration parameters are used not only to adjust and set the controller but also to configure it properly for different applications Woodward 13 EPS 1000 Engine Equipment Protection System Manual SE 4051 Why
71. ve an electronic or programmable control please have the adjustment setting positions or the menu settings written down and with you at the time of the call Woodward 57 We appreciate your comments about the content of our publications Send comments to icinfo woodward com Please include the manual number from the front cover of this publication W wooDwaRD PO Box 1519 Fort Collins CO 80522 1519 USA 1000 East Drake Road Fort Collins CO 80525 USA Phone 1 970 482 5811 e Fax 1 970 498 3058 Email and Website www woodward com ANSI RAB ams FM 57982 BS EN ISO 9001 1994 6 March 2001 gt A oO m kd i m K 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 12 M
72. which exists when the unit is first powered up and when engine speed is below the speed threshold Once speed rises above the threshold set point the speed switch output relay transitions to the Set condition In some cases depending on configuration the speed switch can return to the Reset condition when engine speed drops below a lower threshold reset point or when a manual reset switch is actuated The speed switch may also be configured to latch a Set condition until battery power is cycled Normal vs Reverse Relay Logic A normally configured speed switch channel has the relay de energized in the Reset condition and energized in the Set condition It is possible to configure each channel in Reverse mode such that the relay is energized in the Reset condition and de energized in the Set condition This is helpful in certain conditions where a loss of power to the EPS 1000 should produce the same response as exceeding the set engine speed for example a crank disable feature Configuring a channel in normal mode for a crank disable feature could cause overcranking if power is interrupted to the EPS 1000 Woodward 5 EPS 1000 Engine Equipment Protection System Manual SE 4051 Switch Inputs In addition to monitoring engine speed the EPS 1000 has six switch inputs that can be used to impact the operation of the three output channels 1 3 Engine equipment protection switch inputs EP A EP B and EP C Each channel can
73. y for use on applications with the EPS 1000 controller The tool can be run on any IBM compatible computer that meets the require ments listed in ACT Installation Calibration is a simplified process when using ACT s specially developed EPS Wizard The Wizard prompts the operator for all necessary information and calibrates only those parameters that are required to produce the desired results Once the EPS 1000 module has been programmed ACT may be disconnected The EPS unit will continue to operate normally with ACT either connected or disconnected Bregen bg Figure 2 All purpose Calibration Tool ACT Software CD ROM Woodward 1 EPS 1000 Engine Equipment Protection System Manual SE 4051 Speed Sensors If used in speed switch mode the EPS module will measure speed signal inputs from magnetic pickups ignition or Hall Effect sensors Mini Gen signal generators available from Woodward may also be used Figure 3 Magnetic Pickups available from Woodward Features The EPS 1000 is PC programmable and microprocessor based for accurate and stable set points The following programmable features are standard e Three output channels for independent configuration of various actions Each channel can be configured in one of three modes 1 Speed switch 2 Autocrank controller 3 Glow plug controller e Speed signal input is user selectable for magnetic pickup ignition or Hall Effect sensors Mini Gen sign

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