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APECS® 5000 Electronic Engine Speed Governing System

1. Woodward 19 6 APECS 5000 Electronic Engine Speed Governing System Manual SE 4096 Chapter 3 ACT Operation KEE ACT Installation ACT Kit Contents The All purpose Calibration Tool ACT is used for programming configuring and adjusting and monitoring the APECS controller with your personal computer The ACT kit contains the following e Software CD ROM e Interface module e RS 232 connecting cable e CD ROM Installation Guide Set up Requirements Hardware Requirements e IBM compatible personal computer equipped with a CD ROM drive and a serial port with DB 9 connector capable of 9600 baud communication e Windows software 95 98 Me 2000 XP e 64 MB of available RAM memory and a hard disk with at least 2 0 megabyte of free disk space e SVGA capable video card and monitor capable of 256 colors and 800 x 600 display Software Requirements CD ROM of calibration tool software to run on your personal computer CD supplied with ACT kit Hardware Set up To connect your PC to the APECS 5000 unit a standard RS 232 nine pin cable and a proprietary interface module is required Both are included in the ACT kit NOTE Make sure power to the PC and the APECS unit is off when making connections The engine may or may not be running Connect one end of the RS 232 cable to your PC s COM port Connect the other end of the cable to the interface module Now connect the interface module to the APECS 5000 unit via
2. HELP MENU About ACT File Menu Purpose The File Menu allows you to perform operations related to viewing saving and converting files The following commands are available under the File Menu e Save APECS Cal to File e View Cal File Comments e View Text File e Convert APECS Cal to Text e Convert Cal File to Text e Convert Cal File to Strategy Woodward 23 APECS 5000 Electronic Engine Speed Governing System Manual SE 4096 Save APECS Cal to File This command allows you to save APECS calibration data to a designated file The ACT uploads the calibration set from the APECS controller and saves it to a computer file This operation is usually done after the controller has been calibrated for satisfactory engine performance but can also be done at any other time The data is saved in a binary file format that is not readable To Save APECS Cal to File 1 Choose File gt Save APECS Cal to File ACT will prompt the path where the file will be saved 2 Enter a file name to save the EEEE 2x calibration data to Save in ACT DEG Ae ACT will automatically append the file extension ACT to the file name if you do not specify one Click Save or press lt Enter gt File name My Cal File Save as type cal Files 4CT y Cancel Z ACT will then read all of the current cali Processing Calibration Values bration values from the controller This screen shows the progress SET_SPEED_4 E
3. We recommend using a digital multimeter capable of measuring frequency and duty cycle such as a Fluke 87 1 Check battery voltage for stability and correct value The LED will turn on for one second when the APECS 5000 is first powered up 2 For Model 4100 magnetic pickup check that the speed signal is at least 2 Vrms using the AC volt settings on voltmeter Actuator should go to full travel during cranking The LED will illuminate when it senses an engine speed 3 Check the actuator linkage for binding and backlash 4 Check that the actuator has sufficient force to reach the starting and rated load positions 5 Confirm normal operation of engine under manual control 6 Confirm that the load e g voltage regulator on generator is not inducing instability 7 Try adjusting the gains to achieve stability Fault Codes The APECS 5000 controller is capable of identifying certain fault conditions and alerting the user to them A flashing LED indicates the fault conditions The current fault code list is shown in Table VI Please note the following 1 When power is first applied to the controller the LED will flash just once for one second to indicate that the LED is working 2 If there are multiple faults the LED will flash them all in sequence Count the flash codes to determine the fault conditions or connect the Calibration Tool to observe the fault conditions Use the Display Faults option under the Monitor
4. 0 255 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 seconds AUXILIARY OUTPUT MODE This parameter is used to let the software know how the auxiliary output of APECS 5000 is to be configured See Auxiliary Outputs for settings Calibration Procedures The autocrank feature is enabled by setting AUXILIARY OUTPUT MODE to 4 PTO is not available with autocrank When the auto start switch is made the autocrank output becomes active for AUTOGCRANK CRANK TIME sec or until the engine starts If the engine does not start then the output goes inactive for AUTOCRANK REST TIME sec and then another crank attempt is made The sequence is repeated for AUTOCRANK MAX TRIES If the engine has not started after the maximum crank attempts have been made a fault is flagged When the auto start switch is turned off actuator duty cycle is set to zero to shut down the engine Engine Cranking The engine cranking parameters control how APECS will drive the actuator during cranking Calibration Parameters Needing Configuration 54 Woodward APECS 5000 Electronic Enqine Speed Governing System Manual SE 4096 CRANK 2 RUN Speed transition point indicating engine has gone from crank mode to run mode rpm Once engine rom rises above CRANK 2 RUN rpm it is assumed that the engine is in
5. Convert Cal File to Text 26 Convert Cal File to Strategy cccccccccsssssseccceeeeeeeeeseeeeeeeeseaeeeeeeeeeeesssaaaaeess 27 G IME U a E 27 Change APECS Calibration rrrnnnrrnrrrnrrrrnnnnnnnrrnnrrrnnnnnnnnrrennrrnnnnnnnnsrennnnnnnnn 27 Download Cal File to APECS cccccccnncocccconnncccncnonnccnnnnncononanncnnnnnnnnnnnannnnnnnnnnos 28 Woodward i APECS 5000 Electronic Enqine Speed Governing System Manual SE 4096 Compare APECS Cal to File Cal rrornnnnoronnnnnnnnnvnnnnnnnnrvnnnnnnrnvvnnnnnnnnvnnnnnnnne 30 Change APECS P ass WO dicas adi 31 APECS Calibration Wizard BEE 32 Ma APP A 33 Parameter WIER 33 Parameter Pt es 33 Display Fall aii 35 CONTO Stalin 35 Farameler EE 35 r ele 36 COMU el EE 36 ICID WIGMU or oie 37 FIC ICONOS 37 ADOUAT are 37 Users MANN 37 CHAPTER 4 CALIBRATING APECS FEATURES nuennnnnvvnnnnvennnnnnennnnnvnnnnnuennn 38 EH Eege 38 Sao PICAS io 38 Calibration Categories oooccccccoconccnnccononcnnnccnnancnnnnnnnnncnnnnononnnnnnnonanrnnnnnnnancnns 38 Calb lng an ARP EGS Uli io ets 39 Saving a Calibration Set totie ce cccseccccececeeeeeeeeeseeeseeeeeeeeeeeeeessaaeeeees 39 Calibrating an APECS Unit with a Saved Calibration File 40 Understanding APECS Calibration Parameters cccccccsseeeeeseeeeeeeeeeeeseaeeeeeeas 40 Frequently Asked QUeSTIONS suit OR 40 LIST Ob PAGES ul ci 41 2000 43 Calibration Procedures PID Gains Adiustment 44 PID Gain Sett
6. or use our website and reference Customer Services and then Technical Support Woodward 71 APECS 5000 Electronic Enqine Speed Governing System Manual SE 4096 Technical Assistance If you need to telephone for technical assistance you will need to provide the following information Please write it down here before phoning General Your Name Site Location Phone Number Fax Number Prime Mover Information Engine Turbine Model Number Manufacturer Number of Cylinders if applicable Type of Fuel gas gaseous steam etc Rating Application Control Governor Information Please list all Woodward governors actuators and electronic controls in your system Woodward Part Number and Revision Letter Control Description or Governor Type Serial Number Woodward Part Number and Revision Letter Control Description or Governor Type Serial Number Woodward Part Number and Revision Letter Control Description or Governor Type Serial Number If you have an electronic or programmable control please have the adjustment setting positions or the menu settings written down and with you at the time of the call 72 Woodward APECS 5000 Electronic Engine Speed Governing System Manual SE 4096 Woodward 73 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 AN WOODWARD PO Box 1519
7. 38 Woodward APECS 5000 Electronic Engine Speed Governing System Manual SE 4096 Calibrating an APECS Unit Once the system set up is complete it is fairly easy to calibrate an APECS 5000 controller Before proceeding with calibration please ensure that the controller unit is connected to the COM port and powered Follow the steps below for calibrating your APECS controller unit 1 Ifan icon for the calibration tool exists double click on it to start the ACT software 2 If no con exists click on the Start button highlight Programs find the ACT software and click to start it 3 Make sure the COM port designation in ACT matches the serial port on the back of your PC Follow the procedure outlined in the Configure Menu to change the COM port assignment if needed 4 If you wish to use the Wizard for basic calibration refer to APECS Calibration Wizard The Wizard is an interactive guide to help you get your controller running as quickly as possible 5 If you do not use the Wizard pay particular attention to calibrat ing the travel STEP MAX STEP and direction of travel highest bit of STEP CONFIG of the stepper motor Every count of STEP MAX STEP equals 1 8 so a travel of 72 equates to 40 counts Refer to Actuator Output Calibration Parameters Also calibrate the speed input for the type of speed sensor SPEED TYPE as well as the appropriate values for PULSES PER REV and PULSES PER UPDATE Refer
8. E 10 Controller PINGUL eserse E wicerseneec 12 Speed Sensor Installato Messina das 13 UNE PP E e o A S ee 13 Speed Sensor Wumg 13 MAGNETIC ga GEER NE 13 Actuator amp Linkage Installation cccccccssesceeceeeeeeceeeeeeeeeeseeeesaeeeessaeeeesaseeenaees 14 Engine Speed Setpoint Wiring Analog Input 15 Engine Speed Setpoint Wiring Switched Input 16 PEO Nr 17 AAN OP Ge 18 Uele eu Ge EEE LP 19 Engine Protection Input Wiring cccccsscccccssececceeseeecseseeeceeseeeseseeessaneeessaaeees 19 eigent 19 CHAPTER 3 ACT OPERATION ccsssssccsnsseccnnsssccnnssscnnsssccnnesscnnssscnnasseenneses 20 Lea Ri End e morros inercia 20 ACT Kit Contents edel nach canes sacbessedensaGadeadiaseadedsanecsasbansegesesSadsebbesaacedienedeants 20 Set up Requirements occcccccconccnncccconcnnnconnnncnnnononancnnnonnnancnnnonnnnnrnnnnnnannnnnnnnnnns 20 Hardware SE UD EE 20 SOWIE Sel U EE 21 BASIC ACT NN 22 Running the ACT Software occoooocccnnccccocccnnccononcnnncnonancnnnononancnnnonnnannnnnononanenos 22 Progress Display OCIO EE EEE EEE 22 Moving Around the Goftware 22 ACT Menus amp OptiOnS anoaannnnnnnnnaeanannneonrennnnnnnnernnnrnrreosrnnnrnrrensrnnnrrrreesennnrrreeennne 23 ACT dief le CN 23 o nn cine sth tee Seacniete E E EEE E 23 EE 23 SEP SNE tc tle dees 24 View Cal File Comments ooocccncccccncccnnccononncnnnnnnnnnnnnnnonnnncnnnnnnnnncnnnnonanncnnnnnnnns 25 NS E 26 Convert Commande 26 Convert APECS Cal to Text 26
9. Fort Collins CO 80522 1519 USA 1000 East Drake Road Fort Collins CO 80525 USA Phone 1 970 482 5811 e Fax 1 970 498 3058 Email and Website www woodward com ANSI RAB QMS FM 57982 BS EN ISO 9001 1994 6 March 2001 Za EN fe rr J m J Woodward has company owned plants subsidiaries and branches as well as authorized distributors and other authorized service and sales facilities throughout the world Complete address phone fax email information for all locations is available on our website 04 9 M
10. Once all the values are read ACT will prompt you to add comments to Do you wish to edit the new Cal File Comments the ACT file to aid in later identification 3 If you click Yes the comment editor screen will appear To enter comments type them one ata 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 al al el Ge on them and then clicking Delete or by nest ok pressing lt Del gt 24 Woodward APECS 5000 Electronic Engine Speed Governing System Manual SE 4096 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 a T UL CV doochaard CT Tool Cal tool stuff 1 407 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
11. Repair is available for the majority of standard products in the field This program offers you repair service for your products with the advantage of knowing in advance what the cost will be All repair work carries the standard Woodward service warranty Woodward Product and Service Warranty 5 01 1205 on replaced parts and labor Flat Rate Remanufacture Flat Rate Remanufacture is very similar to the Flat Rate Repair option with the exception that the unit will be returned to you in like new condition and carry with it the full standard Woodward product warranty Woodward Product and Service Warranty 5 01 1205 This option is applicable to mechanical products only Returning Equipment for Repair If a control or any part of an electronic control is to be returned to Woodward for repair please contact Woodward in advance to obtain a Return Authorization Number When shipping the item s attach a tag with the following information name and location where the control is installed name and phone number of contact person complete Woodward part number s and serial number s description of the problem instructions describing the desired type of repair CAUTION To prevent damage to electronic components caused by improper handling 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 followin
12. boards e Do not touch the components or conductors on a printed circuit board with your hands or with conductive devices IMPORTANT DEFINITIONS WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION indicates a potentially hazardous situation which if not avoided could result in damage to equipment NOTE provides other helpful information that does not fall under the warning or caution categories Woodward Governor Company reserves the right to update any portion of this publication at any time Information provided by Woodward Governor Company is believed to be correct and reliable However no responsibility is assumed by Woodward Governor Company unless otherwise expressly undertaken Woodward 2004 All Rights Reserved APECS 5000 Electronic Engine Speed Governing System Manual SE 4096 Contents BEE CHAPTER 1 UNDERSTANDING THE SYSTEM aunnunnnnunnunnunnnnnnnnnnunnunnunnnnnnnnnnunn 1 System gt gt ENE 1 EN 2 PE SON vet 2 Calibration Tool ACTA 3 o A 3 Stepper Motor Al UA Luer 3 Stepper Motor DIMENSIONS vasos ida 5 Brackets and Linkage A 6 FAUST el 7 Engine Speed Select Option Table 8 CHAPTER 2 INSTALLING THE HARDWARE coccoccoconcoconcanoncanoncannaranonrancnnancnnos 9 Wiring Guidelines rrrnnnnrrnnrnnnnnnvvrrnnnnnrrnnnnnnnnrrnnnnnnnnsennnnnnnnssnnnnnnnnsrnnnnnnsnsrnnnnnnsnssen 9 Controller InstallatiOM NEE 10 Controller Wiring
13. by wire no IVS PTO available Drive by wire IVS open at idle Drive by wire IVS open at idle Drive by wire IVS closed at idle Drive by wire IVS closed at idle PTO available Drive by wire PTO available brake mode Use external pot to adjust set speed between SET SPEED MIN and SET SPEED MAX PTO is available where indicated and allows switching from pot selected speed to switch selected speed Auxiliary output can be configured to indicate the PTO state Ramp rate limits are still in effect Use pedal pot to adjust set speed between SET SPEED MIN and SET SPEED MAX with additional fault management Controller must see minimum peddle position before command for off idle will be accepted Can be used with an IVS idle verification switch PTO is available where indicated and allows switching from pedal pot selected speed to switch selected speed Auxiliary output can be configured to indicate the PTO state Ramp rate limits are still in effect Uses IVS as brake input will do automatic return to idle SET SPEED MIN when IVS is active for longer than BRAKE DELAY seconds Otherwise similar to Mode 013 APS calibration mode See External Pot Calibration EI DES kd Drive by wire no IVS Gi Allows an external pot from various applications to interface properly with the controller Reverse pot option reverses speed increase decrease relationship to a clockwise rotation of
14. command allows you to designate the proper COM port for your PC to enable communication between the ACT and the APECS controller To Configure the Serial Port ACT Communications Configuration E xX 4 F th Serial Controller Conmection r Demo Mode i rom the main menu screen 2 Com 1 i EPS 1000 Cancel choose Configure gt Custom Ge Ee EE Serial Port The application will a display the following screen Custom C APECS 3000 C APECS 4000 2 Choose a port and Click OK This C APECS 4500 screen will be displayed on appli EE cation startup if a controller cannot be found at the last selected port and can be changed any time after the application has started 36 Woodward APECS 5000 Electronic Enqine Speed Governing System Manual SE 4096 Demo Mode This mode will use a calibration file Demo 000 and use random numbers for values requested from the controller COM 1 COM 2 This mode will look for a controller attached to the selected serial port An error message will be displayed AFTER you click OK if a controller cannot be found or if the port cannot be opened COM ports outside of this range can be used by editing the default COM port registry key for this application Help Menu The Help Menu provides access to the online user s manual and other information helpful to your use of the Calibration Tool The following commands are available under the Help Menu e Help Topics e About ACT e User s M
15. converted text file See Convert APECS Cal to Text and Convert Cal File to Text commands View Cal File Comments This command allows you to display the comments that are attached to a calibration file Users 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 ER My Network Places CAD System Files ACT will display a list of files on the left isjoemo oo LJ EF Pdf s side of the screen with file comments on the right File name A 2 Use the Up and Down arrow keys to Files of type Cal Files 000 ACT Close highlight the desired calibration file T Open as read only ACT extension and view the 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 l Woodward 25 APECS 5000 Electronic Enqine Speed Governing System Manual SE 4096 View Text File This command is a convenient way to view text files 1 Choose File gt View Text File ACT will prompt for a text file to view 2 Select a file and click OK ACT will open the selected file with the default viewer for that file type Convert Commands The Save APECS Cal to File command discussed earlier stores the calibration data as a
16. matches the Please enter the controller password current password lf the password matches the Change button is E Change Cancel enabled Password Vald Click Change to change controller password 3 Click Change and the application will prompt for the new password Password Management x Enter new Password Change Cancel OK Status _ Cancel or Password Change Mode 4 Enter the new password It should be one word no spaces and up to 11 characters long Once entered click OK The application will prompt to reenter the password to make sure that it was typed in properly 5 Re enter the password and click x OK If the two entries of the new password are equal the new password will be encoded and Re enter new password saved in the controller Passwords are upper and lower case Se Change Cancel sensitive Password Change Moie After changing your password please record it in a safe place for future reference To revert to no password protection change APECS password to peg which is the default password Woodward 31 APECS 50000 Electronic Engine Speed Governing System Manual SE 4096 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 w
17. module AN WARNING An overspeed shutdown device independent of the APECS system should be provided to prevent loss of engine control that may cause personal injury or equipment damage Woodward 1 APECS 5000 Electronic Engine Speed Governing System Manual SE 4096 ENGINE SPEED SIGNAL STEPPER MOTOR ACTUATOR SPEED SETPOINT SWITCHES ANALOG SPEED INPUT APECS CONTROLLER PC IDLE VERIFICATION SWITCH CALIBRATION TOOL PTO ENABLE SWITCH ENGINE PROTECTION SWITCH AURILARY OUTPUT Figure 1 APECS 500 Engine Control System System Components The four main components of a complete APECS installation are the APECS controller speed sensor stepper motor actuator and linkage A fifth device the All purpose Calibration Tool ACT is required for initial configuration and diagnosis of the controller In addition to the main components and depending on the features selected several subcomponents such as switches and potentiometers may be required Each component contributes to the overall performance of the system and shortcomings in any of the components will detract from total system performance APECS Controller The APECS 5000 series controller is an electronic engine governor that provides a means of controlling and limiting engine speed by adjusting the fuel control lever with a stepper motor actuator The APECS controller may be programmed to operate at a single set speed or respond to operator commands from a
18. moving past the desired position it will work to assist the motion Similarly if a second step command occurs while the rotor is moving in a backwards direction motion will be hindered and steps may be lost APECS 5000 has the ability to specify the stepper motor pulse interval and a brief delay when reversing direction or following a start stop start command The primary differences between a stepper motor and a proportional solenoid actuator are outlined in the chart below Force Size Low 4 Woodward APECS 5000 Electronic Engine Speed Governing System Manual SE 4096 Stepper Motor Dimensions Mating Connector Delphi 12162188 B Mating Terminal Delphi 12124075 4 required SE 69 54 mm Ka 6 35 mm SY 97 PGR 6 d PINS CONNECTOR 69 17 65 mm Figure 3 Stepper Motor Actuator Dimensions ara 9267 mm 1037 1 047 26 33 mm 26 39 mm r G267 mm 138 Past mirg 4 PLALES M3 SCREW MOUNTING HOLES 1 ACTUATOR ROTATING DIRECTION Figure 4 Mounting Dimensions Woodward 5 APECS 5000 Electronic Enqine Speed Governing System Manual SE 4096 Brackets and Linkage The actuator should be mounted to a bracket that has been designed for adequate strength and minimum vibration The actuator is designed to accept M3x 5 metric nuts THROTTLE SHAFT The linkage connects the actuator shaft to the EE engine control lever A good linkage allows for COUPLING misa
19. pot 48 Woodward APECS 5000 Electronic Enqine Speed Governing System Manual SE 4096 CAUTION If a drive by wire mode is being used 003 013 023 103 113 203 213 the engine is not allowed to start up in PTO mode PTO is locked out until the engine has started and the PTO switch is transitioned from its off position Switch Configuration Modes Use the switched inputs and speed setpoint parameters to set up to four discrete speeds and set ramp rates between speeds OR use the inputs to manually increase or decrease speed at preset rates with variable speed control Refer to Auxiliary Output Wiring for wiring switch inputs Table 4 Switch Configuration Modes CONFIGURATION DESCRIPTION MODE A single engine speed is commanded The engine is started and transitions from crank mode to run mode The commanded engine speed will increase from SET SPEED MIN to SET SPEED WARMUP at the 1 SINGLE SPEED RAMP UP RATE Engine speed remains at the warm up speed for WARMUP TIME seconds after which the engine speed either increases at RAMP UP RATE or decreases at RAMP DOWN RATE to SET SPEED 1 switch is used to select between two set speeds The engine is started and transitions from crank mode to run mode The commanded engine speed will increase from SET SPEED MIN to SET SPEED WARMUP at the RAMP UP RATE 2 TWO SPEED Engine speed remains at the warm up speed for WARMUP TIME seconds after which the engine s
20. run mode CRANK DUTY CYCLE The fixed duty cycle used to drive the actuator when the engine is cranking percent May be calibrated to a maximum duty cycle for diesel engines that require full rack for starting or a minimum duty cycle for some spark ignition engines that require closed throttle for starting NOTE This parameter is preset to a value that will work with most engines and applications Entering new values for these parameters is optional KEY ON DUTY TIME The actuator will be driven at CRANK DUTY CYCLE following key on reset for KEY ON DUTY TIME in seconds while there is no input speed signal Once a valid speed signal is detected normal operation ensues This is useful for applications that do not generate a speed input signal at crank e g genset which senses engine speed from the generator output When using this feature the duty cycle does not cut back until a valid input speed signal is seen or the timeout period is up lf there is never a valid input speed the actuator will continue to be driven at CRANK_DUTY_CYCLE even if the engine is running This could lead to an overspeed situation Default value O Calibration Procedures CRANK_DUTY_CYCLE may be calibrated to a maximum duty cycle for diesel engines that require full rack for starting or a mid range duty cycle for some spark ignition engines that require a partially open throttle for starting In run mode control is closed loop the actuator is driven a
21. signals are working and synchronized Hu O O Electrical noise may be entering controller Controller unit Check wiring shielding and connections to controller failed Yes Cycle power to engine If controller still does not work consult factory Check wiring and actuator for open circuit or short to Stepper motor ground driver fault O O O Replace controller Engine speed Active only in Autocrank mode input signal missing Check speed sensor wiring Check starter motor Autocrank unable to start engine No Check fuel Auxiliary output is shorted Battery voltage Yes Reduce voltage if it is greater than 38 Vdc too high Stepper motor Check stepper motor wiring and linkage pee ne Yes Check STEP PRD and STEM 9PAWard Check the lamp or relay hooked to the output If fault is still present consult factory O N respond to command Check for excessive engine load APECS 5000 Electronic Engine Speed Governing System Manual SE 409 Calibration Setup amp Configuration Parameters Flowchart Step 1 Set up the APECS Calibration Tool ACT Computer AMES Y EG y Sail Step 2 Configure speed input 6 Step 3 C
22. the switches the commanded engine speed is ramped to the new set speed 4 FOUR SPEED A momentary switch is used to ramp desired engine speed either up or down The engine is started and transitions from crank mode to run mode The commanded engine speed will increase from SET SPEED MIN to SET SPEED WARMUP at the RAMP UP RATE Engine speed remains at the warm up speed for WARMUP TIME seconds after which the user 5 VARIABLE may select a new speed by using the switches which will SPEED either increase or decrease engine speed A brief pressing of the switch will change engine speed by one rpm Holding the switch closed longer will ramp the engine speed command first at a slow rate then at either RAMP_UP_RATE or RAMP_DOWN_RATE depending on which direction the switch is being pressed The engine speed command will never ramp above SET_SPEED_MAX or below SET_SPEED_MIN External Pot Calibration This feature allows an external pot from a variety of applications to interface properly with the APECS 5000 Refer to Table 4 for mode configurations and descriptions Calibration Parameters Needing Configuration EXTERNAL_ANALOG_MODE Allows the external analog input to be configured in a variety of ways Calibration Procedures The calibration procedure is automatic Simply set the parameter EXTERNAL _ ANALOG_MODE to 255 refer to Table 4 and run the external pot or pedal up and down through its full range of travel The con
23. to Speed Input Configuration Parameters 6 Beyond basic calibration there are many parameters associated with APECS that can help enhance the performance of your engine Read the section on Understanding APECS Calibration Parameters and decide on the parameters you would like to adjust 7 Access Change APEGS 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 engine performance has been achieved 9 You do not need to save the new calibration settings All settings are automatically saved in the controller and remain in memory after shutdown Saving a Calibration Set to File After satisfactory engine performance is achieved it is recommended that you save the calibration set to a file e A saved file allows you to experiment with other calibration settings and still be able to recall the saved calibration set e A saved calibration set can be used for configuring additional APECS units To Save a Calibration Set to File 1 Access the File Menu to activate the Save APECS Cal to File command Woodward 39 APECS 5000 Electronic Engine Speed Governing System Manual SE 4096 Enter a file name to save the calibration data to a designated file When prompted to edit the comment list enter information that will help you ke
24. to call in the event of an unexpected outage or in advance of a scheduled outage to request a replacement control unit If the unit is available at the time of the call it can usually be shipped out within 24 hours You replace your field control unit with the like new replacement and return the field unit to the Woodward facility as explained below see Returning Equipment for Repair later in this chapter Charges for the Replacement Exchange service are based on a flat rate plus shipping expenses You are invoiced the flat rate replacement exchange charge plus a core charge at the time the replacement unit is shipped If the core field unit is returned to Woodward within 60 days Woodward will issue a credit for the core charge The core charge is the average difference between the flat rate replacement exchange charge and the current list price of a new unit Return Shipment Authorization Label To ensure prompt receipt of the core and avoid additional charges the package must be properly marked A return authorization label is included with every Replacement Exchange unit that leaves Woodward The core should be repackaged and the return authorization label affixed to the outside of the package Without the authorization label receipt of the returned core could be delayed and cause additional charges to be applied 68 Woodward APECS 5000 Electronic Enqine Speed Governing System Manual SE 4096 Flat Rate Repair Flat Rate
25. to specify the delay in seconds for automatic return to idle once the IVS input indicates no load on the engine Range 0 31 875 seconds Once the timer times out SET SPEED MIN will be commanded regardless of whether the controller is in pedal mode or PTO mode RAMP DOWN RATE Rate at which command engine speed decreases from one set point to a lower set point rom second RAMP_UP_RATE Rate at which commanded engine speed increases from one set point to a higher set point rpm second SET SPEED 1 Preset engine speed 1 rom Used when SWITCH_CONFIGURATION 1 4 SET SPEED 2 Preset engine speed 2 rom Used when SWITCH_CONFIGURATION 2 4 SET SPEED 3 Preset engine speed 3 rpm Used when SWITCH CONFIGURATION 3 4 SET_SPEED 4 Preset engine speed 4 rom Used when SWITCH CONFIGURATION 4 SET_SPEED_MAX Highest engine speed command possible when using push button switches to ramp engine speed up rpm SWITCH_CONFIGURATION 5 Also used to specify the maximum rom commanded with an analog input SET SPEED MIN Lowest engine speed command possible when using variable speed mode to ramp engine speed down rpm SWITCH CONFIGURATION 5 Also used to specify the minimum rom commanded with an analog input 46 Woodward APECS 5000 Electronic Enqine Speed Governing System Manual SE 4096 SET SPEED TRIM Amount speed may be trimmed with external pot above below set speed SET SPEED WARMUP Engine speed set point
26. used immediately after engine has started running rpm SPEED DEGREASE DELAY When in multi speed mode 2 3 or 4 and the speed switch input is changed to select a lower speed this is the delay before the engine speed command is ramped to a new lower speed seconds This is useful for applications that are continuously switched on and off such as welding machines WARMUP TIME Length of time to hold engine at warmup speed immediately after engine has started running seconds Setting WARMUP TIME to zero disables the warmup feature NOTE All switch inputs are switched to Vbat External Analog Input Calibration with IVS Use the external analog input for a variety of functions such as 1 Pedal position sensor with idle verification switch 2 Remote speed adjustments and 3 Trim potentiometer See Auxiliary Output Wiring for wiring analog inputs Woodward 47 APECS 5000 Electronic Engine Speed Governing System Manual SE 4096 Table 3 External Analog Input Modes No external sin input Use Su switch or momentary switch Trim mode Trim mode reverse pot BEST external pot to trim the selected set speed The speed selected by the set speed switches is adjusted by plus or minus SET SPEED TRIM The set speed is bounded by SET SPEED MIN and SET SPEED MAX Set speed with pot Set speed with pot PTO available Set speed with reverse pot Set speed with reverse FG PTO available Drive
27. your application Engine Speed Setpoint Wiring Analog Input The APECS 5000 controller features an analog speed input for mobile or stationary applications To incorporate this feature wire the analog input to an external pot which must be connected to a pedal Use Figures 9 amp 10 as a guide to wire the input to your application Potentiometer resistances of 3K 5KO are recommended Once the analog speed input is wired refer to the APECS Calibration section to configure the appropriate parameters If use of an idle verification switch IVS is desired hook up Pin J2 5 from the controller to the idle verification switch on the pedal Refer to the manufacturer s instructions or OEM manual The other side of the switch should be connected to battery voltage see Figure 10 During engine operation if the IVS switch and pedal pot do not agree the engine will operate at minimum speed only Non potentiometric analog voltages may also be used to command set speed The analog voltage 0 5 volt max should be wired across terminals J2 12 positive and J1 4 ground APECS 5000 VREF J2 11 APP J2 12 SRTN J2 2 gt Figure 9 Analog Input Switch APECS 5000 VREF 33 11 APP 2 12 SRTN J2 2 MS 2 5 Figure 10 Analog Input Switch with IVS Wiring Woodward 15 APECS 5000 Electronic Enqine Speed Governinq System Manual SE 4096 Engine Speed Setpoint Wiring Switched Inputs The APEC
28. 0 to the negative side of one coil primary May not work with ignition systems that vary the coil charging voltage eg Ford TFI Woodward 13 APECS 5000 Electronic Engine Speed Governing System Manual SE 4096 Magneto Ignition Typically found on small 1 and 2 cylinder engines Connect Pin J1 10 to the primary engine kill wire and Pin J1 3 to the engine block On multi cylinder engines confirm that there are no diodes between the primary connection and J1 10 Hall Effect Located next to an engine driven gear Connect Pin J1 10 to the sensor output and Pin J1 3 to the negative side of the sensor The third sensor lead should be connected to battery positive J1 9 NOTE It is beyond the scope of this manual to discuss detailed speed sensor selection and installation for all possible applications Please contact the factory for specific information concerning your application Actuator amp Linkage Installation 1 The stepper motor actuator may be attached to the throttle either by means of a shaft coupling or by means of a lever and link A coupling should be tolerant of misalignments in shaft angle and shaft offset 2 Select or design a bracket that correctly aligns the actuator shaft and throttle shaft The bracket must be able to withstand the vibration level of the engine or application The actuator is provided with slots suitable for use with metric M3 x 5 hex nuts 3 The linkage must ha
29. 00 O e el Speed Select 1 O pf Speed Select 2 No Connections 16 Woodward APECS 5000 Electronic Engine Speed Governing System Manual SE 4096 d THREE SPEED MODE A three position rotary switch is used to select among three set speeds Vbatt le Ybatl APECS 5000 IS S J2 7 2 Speed Select 1 J2 8 Speed Select 2 J1 4 FOUR SPEED MODE A 4 position rotary switch with two diodes is used to select among four set speeds Kai Ties Ulead A APECS 5000 Speed Select 1 Typical diodes that can be used with Speed Select 2 the four speed mode are 1N4001 1N4002 up to 1N4007 VARIABLE SPEED MODE A momentary switch is used to ramp desired engine speed either To Vbatt up or down Vbatt PTO Switch Wiring The APECS 5000 controller offers a Power Take off PTO feature that allows the controller to switch from pedal input to switched inputs for mobile applications Alternately the PTO input may be configured for the autocrank feature APECS 5000 Vbatt To use the PTO input wire a switch to Pin J2 6 on the controller Once the input is wired refer to APECS Calibration section to configure the appropriate parameters The PTO input is switched to Vbat PTO J2 6 Woodward 17 APECS 5000 Electronic Enqine Speed Governinq System Manual SE 4096 Auxiliary Output Wiring Because a stepper motor will not automatically return to the
30. 023 adcnts APP AD ORL adcnts APP FULL DEADBAND 6 5 adcnts APP IDLE DEADBAND 6 5 adents APP MIN CAL 230 0 240 5 adcnts APP NOISE CNT 31 30 NONE APP RANGE CAL 550 0 540 5 adcnts AUTOCRANK CRANK TIME 11 0 10 0 sec AUTOCRANK MAX TRIES 5 6 NONE AUTOCRANK NS TIME 1 0 1 5 sec AUTOCRANK_REST_TIME 16 0 15 0 sec AUXILIARY OUTPUT 2 MODE 1 0 NONE AUXILIARY OUTPUT MODE SS AUX LAMP INRUSH TIME 4 AUX OUTPUT 2 RPM 1500 0 AUX OUTPUT RPM 1501 0 BRAKE DELAY 1 CRANK 2 RUN 1100 0 CRANK DUTY CYCLE 1 000 DERIVATIVE CATH 0 262 DERIVATIVE GAIN IDLE 0 262 You may select Save to File if you would like to save a permanent record of the file compare You will then be asked to select a destination directory and file name 30 Woodward APECS 50000 Electronic Engine Speed Governing System Manual SE 4096 Change APECS Password This command allows you to add or change a password to protect certain calibration features The option is useful for example to prevent unauthorized changes to a known good calibration set in the APECS unit By default the APECS unit is not password protected To Change APECS Password egen 1 Choose Calibrate gt Change APECS Password You will be prompted for the Please enter the controller email current password Ehange Cancel OF en reg re Enter password and click OK Password Management 1 xX 2 The application will query the controller to verify that the entered passwo rd
31. CMOTOR controller PTO input switch to Vbat RELAY The diagram at left shows how to wire the autocrank feature Once the input is wired refer to APECS Calibration section to configure the appropriate parameters NOTE When the autocrank feature is used the PTO switch input cannot be used for other features WARNING If using the autocrank feature make sure you calibrate the controller for the autocrank feature prior to hook up If controller is not calibrated for autocrank and the crank motor relay is hooked up the engine may start as soon as power is applied to the controller Refer to the autocrank calibration section in Chapter 4 Engine Protection Input Wiring Optional Feature The APECS 5000 controller offers an engine protection shutdown feature to safeguard against adverse operating conditions such as low oil pressure or high coolant temperature The engine protection EP input is a switched input similar to the set speed inputs This input must switch to ground potential Figure 13 shows how to wire the EP input To use more than one sensor simply wire the sensors in parallel as shown in Figure 14 Once the input is wired refer to the APECS Calibration section to configure the appropriate parameters APECS 5000 Vbatt APECS 5000 AUX J2 4 AUX J2 4 or AUX 2 J2 3 or AUX 2 J2 3 Low Side Driver Low Side Driver Figure 13 EP Input Single Sensor Figure 14 EP Input Multiple Sensor
32. DE Determines operating mode of the stepper motor Default value 0 0 normal closed loop governing mode 1 step position follows pedal position provided EXTERNAL ANALOG MODE is non zero 2 step position STEP_CAL 3 stepper motor sweeps continuously between 0 and STEP MAX STEP STEP CAL When STEP MODE 2 specifies desired stepper motor position Default value 0 steps STEP CONFIG Bit field specifying stepper motor direction of travel and resolution Default value 00000011 X 00000YZ Where X direction bit Y Z resolution 00 whole steps 01 half steps 10 quarter steps 11 eighth steps STEP_PRD Stepper motor pulse period in microseconds Setting STEP_PRD too low will cause the stepper motor to lose count and go to the incorrect position Default value 4000 usec STEP_WAIT Stepper motor delay period in microseconds when reversing stepper motor direction and doing stop start operations Setting STEP_WAIT too low will cause the stepper motor to go to the incorrect position Calibration Procedures 1 After installing stepper motor to bracket and connecting linkage apply power to APECS 5000 Make certain engine is not running and cannot start 2 Ifa potentiometric input is being used make certain that it has been calibrated and EXTERNAL ANALOG INPUT is set to a non zero value e g 2 Refer to sections 4 4 1 and 4 4 3 3 Set STEP MODE 1 to configure the stepper motor to follow the potent
33. DERIVATIVE_GAIN SPEED_DECREASE DELAY INTEGRAL_GAIN PROPORTIONAL_GAIN SET_SPEED_WARMUP MASTER GAIN WARMUP_TIME External Pot Calibration Ge Me PP The external pot calibration needs to be RPM RPM calibrated for use in the desired speed mode A gt The calibration process is automatic Simply i af Actual RPM set the parameter SE EXTERNAL_ANALOG_MODE to 255 and run E E gt the external pot or pedal through it s full range of travel The controller will i i 5 z p automatically learn and store the minimum PID Gains too high Integral gain too high or and range values in tits memory Set derivative gain too low EXTERNAL_ANALOG_MODE back to the P sdesired speed mode when finished Desired RPM S Actual RPM ei Actual RPM a Desired RPM TIME TIME Y SET SPEED WARMUP PID Gains too low Derivative gain too high WARMUP TIME RAMP DOWN RATE RAMP UP RATE SPEED DECREASE DELAY PTO only Remove Load Desired RPM S N Actual RPM P NS Add Load TIME TIME Integral gain too low Desired response 66 Woodward APECS 5000 Electronic Enqine Speed Governing System Manual SE 4096 Glossary of Technical Terms ACT All Purpose Calibration Tool Software PC software program for configuring and calibrating the APECS controller Actuator Device that converts an electrical signal from the APECS controller to an output shaft position APECS 5000 uses a stepper motor a
34. Menu 3 If there are no faults the LED will flash once at reset and from then on indicate the detection of engine speed A continuous ON LED indicates that a valid engine speed is being sensed 4 The controller will attempt to shut down for some faults and will not permit starting after reset with faults 1 5 and 8 Woodward 61 APECS 5000 Electronic Engine Speed Governing System Manual SE 4096 FLASH ENGINE CODE FAULT SHUTDOWN CORRECTIVE ACTION dd oc Yes Calibrate APECS unit not calibrated Check parameter settings Overspeed criteria may be too sensitive Check for electrical noise entering controller Engine speed Yes Check wiring and connections excessive Check case ground Make sure linkage moves freely without backlash Check tip of speed sensor Check parameter settings Engine speed unusually low Yes Check linkage and the actuator travel Ensure that load is not greater than engine capacity Engine shutdown due to engine Yes protection input Check parameter settings Check what may have triggered the protection input If calibration file is available download calibration file Factory and cycle power again settings lost External pot out of range Accelerator position idle switch conflict Yes If controller still does not work or if no calibration file is available consult factory Verify that pot is wired correctly Recalibrate external pot Verify that
35. N 750 RPM discreet speeds or use momentary OR KEY ON DUTY TIME 0 switch to increase or decrease speed TZ at preset rates oo Engine Protection Input ENGINE_PROTECT_RUN_TIME default 8000 disabled Overspeed Underspeed Tim Mode Speed Protection All disabled by Switch Trim Pot A OVERSPEED_RPM default Use external pot to trim the selected D t speed AND UNDERSPEED_RPM set Sp UNDERSPEED RUN TIME Auxiliary Output Default AUXILIARY OUTPUT MODE 0 Set Speed with pot Speed Pat R AUXILIARY OUTPUT RPM 0 Use external pot to adjust set speed P PTO is available Droop Governing Default DROOP STEP MAX 0 Speed Pot 4 pad DROOP_STEP_MIN 0 OFF fed ON TE DROOP_PERCENT 0 dr PTO PTO Input EXTERNAL ANALOG MODE SWITCH CONFIGURATION Drive by wire Similar to set speed with pot but with additional fault management Suitable gt for pedal applications p PTO is available Idle verification switch is available Speed gt Switch p PTO dep p gt 64 Woodward APECS 5000 Electronic Enqine Speed Governing System Manual SE 4096 Step 6 Select appropriate external analog mode Use speed switch EXTERNAL ANALOG MODE 000 Step 7 Calibrate the required parameters to configure engine speed input Use momentary switch EXTERNAL ANALOG MODE 000 SWITCH CONFIGURATION 1 4 SET SPEED 1 4 Trim Mode EXTERNAL ANALOG MODE 001
36. No of pulses until PULSES PER UPDATE next engine speed update Time autocrank AUTOCRANK CRANK TIME holds crank solenoid on sec AUTOCRANK MAX TRIES Number of autocrank attempts Rest time between AUTOCRANK REST TIME autocrank attempts sec Engine Start Calibration Kickoff duty cycle CRANK DUTY CYCLE for open loop cranking 0 945 Time at no start KEY ON DUTY TIME and key on to drive duty cycle Engine run time ENGINE PROTECT RUN TIME before checking switch 8000 disabled Switch delay before ENGINE PROTEGCT TIME engine protection shutdown 8000 1000 Diagnostics Calibration OVERSPEED RPM Actuator shutdown speed max UNDERSPEED RPM Actuator shutdown speed min Run time before UNDERSPEED RUN TIME O underspeed is checked 6 42 Woodward APECS 5000 Electronic Engine Speed Governing System Manual SE 4096 CATEGORY PARAMETER DESCRIPTION od Drive aux output AUX_OUTPUT_RPM when above this 700 engine rpm status lamp use RPM AUXILIARY OUTPUT MODE ae shutdown autocrank mimic LED DROOP_PERCENT a o Desired step posn when SES STEP_MODE 2 STEP_CONFIG X0000011 X direction 00000011 Actuator Output 0 normal closed loop governing 1 step follows analog STEP_MODE Mpal 2 step posn STEP CAL 3 sweep mode STEP PRD Duration of each step 3000 USEC STEP WAIT Delay on stepper 4000 reversal or stop start Calibration
37. PTO switch to select between pedal pot and speed switches Drive by Wire mode assures that the engine will never start up ata high speed Commanded speed will remain at idle until the pedal returns to idle The PTO input must undergo an off to on transition before starting PTO mode 8 Woodward APECS 5000 Electronic Engine Speed Governing System Manual SE 4096 Chapter 2 Installing the Hardware AE EEES When installing the APECS hardware be aware that some of the options selected may also require hardware setup see list below Hardware required for optional features is not provided or sold by Woodward Take adequate protection to ensure personal and equipment safety and follow the suggested installation sequence given below Install main components Review Wiring Guidelines Controller Speed Sensor Actuator and Linkage Install optional components hardware installation required Autocrank Auxiliary Output Engine Protection Input Speed Setpoint Switched Input Speed Setpoint Analog Input PTO Switch Input Detailed instructions for installation and wiring are provided in the following pages Wiring Guidelines APECS 5000 has two 12 pin Deutsch connectors labeled J1 grey and J2 black Mating connectors may be purchased from Woodward part number SA 4490 or from a Deutsch distributor Deutsch part numbers are as follows J1 Grey DTM06 12SA J2 Black DTM06 12SB Sockets pins 12 per co
38. Pulses per revolution number of cylinders 2 for multi cylinder engine with distributor PULSES PER REV FAQ How does PULSES PER REV 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 REV The number of ignition pulses per engine revolution will vary depending on the engine type Factors that must be known include how many cylinders the engine has whether there is a distributor and if a waste spark is generated Are there any general guidelines Yes Single cylinder engines typically use a magneto with a firing spark and a wasted spark The firing spark occurs at the end of the compression stroke once every 2 engine revs The wasted spark occurs at the end of the exhaust stroke 360 later 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 REV must be an integer no half pulses allowed The ignition sign
39. S 5000 controller has two switched speed inputs for multiple speed settings This is convenient for customers who need more than one speed for engine governing i e idle speed power speed setting or low power high power setting To incorporate these switched inputs determine the speed mode desired based on your application The five modes available are Single Speed Two Speed Three Speed Four Speed or Variable Speed After determining the speed mode select the switch hardware best suited for your application Switch hardware is not provided or sold by Woodward Choose a switch designed for low currents 5 to 20 mA Avoid choosing higher current devices that rely on the current to clean the switch con tacts A dry circuit switch is recommended The speed select switch is typically mounted on the control panel but can be mounted in any other suitable location Use the accompanying diagrams as a guide for wiring the selected switch to your controller Once the speed select switch is wired you need to calibrate Engine Set Speed Calibration parameters to make the feature work Please refer to APECS Calibration section to configure the appropriate parameters according to the selected speed mode Vbatt SINGLE SPEED MODE APECS 5000 No switch is needed Speed Select 1 No Connections Speed Select 2 No Connections TWO SPEED MODE A toggle switch is used to select SS between two set speeds Tie et A APECS 50
40. S 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 APECS password is added or changed the new password is stored in the unit as well as in any calibration file saved after the change During a Download Cal File to APECS operation if the password stored in the calibration file matches the password in the unit ACT will readily download the calibration to the APECS unit However if the password stored in the calibration file does not match the password in the APECS unit ACT will alert you of a password mismatch Please follow the steps below to complete the download operation 1 When a password mismatch is detected the ACT displays a message Cal File password differs from that of the APECS unit Download the Cal File password to the APECS unit 2 If you answer Yes to this message see note below the calibration file will be downloaded and the password in the APECS unit will be changed to match the password stored in the calibration file 3 If you answer No to this message the calibration file will still be downloaded but the password in the unit will remain unchanged NOTE Gi Before answering Yes to the message make sure you know the password in the calibration file If you do not know the password you will not be able to access the password protected features under the Cal
41. SE 4096 MW WOODWARD APECS 5000 Electronic Engine Speed Governing System For use with Stepper Motor Actuators User s Manual Manual SE 4096 A A WARNING Read this entire manual and all other publications pertaining to the work to be performed before installing operating or servicing this equipment Practice all plant and safety instructions and precautions Failure to follow instructions can cause personal injury and or property damage The engine turbine or other type of prime mover should be equipped with an overspeed shutdown device to protect against runaway or damage to the prime mover with possible personal injury loss of life or property damage The overspeed shutdown device must be totally independent of the prime mover control system An overtemperature or overpressure shutdown device may also be needed for safety as appropriate CAUTION To prevent damage to a control system that uses an alternator or battery charging device make sure the charging device is turned off before disconnecting the battery from the system Electronic controls contain static sensitive parts Observe the following precautions to prevent damage to these parts e Discharge body static before handling the control with power to the control turned off contact a grounded surface and maintain contact while handling the control e Avoid all plastic vinyl and Styrofoam except antistatic versions around printed circuit
42. STEP MAX STEP Actuator travel in steps 1step 1 8 Woodward 43 APECS 5000 Electronic Enqine Speed Governing System Manual SE 4096 Calibration Procedures PID Gains Adjustment These parameters allow proportional integral and derivative gains to be programmed by the user Calibration Parameters Needing Configuration DERIVATIVE GAIN Engine speed governor derivative gain unitless Derivative gain is used to improve stability Increase derivative gain until response has a slight overshoot on load transients INTEGRAL GAIN Engine speed governor integral gain unitless Integral gain is used to remove steady state errors Increase integral gain until speed begins to oscillate and then decrease until oscillation stops If oscillations do not occur bump actuator lever then decrease integral gain until oscillation stops PROPORTIONAL_ GAIN Engine speed governor proportional gain unitless Proportional gain is used to improve response time A maximum amount of proportional gain should be used while still maintaining stability Increase proportional gain until speed begins to oscillate then decrease until oscillation stops If oscillations do not occur bump actuator lever then decrease proportional gain until oscillation stops MASTER_GAIN As a multiplier to the PID gains master gain is used to increase or decrease the combined derivative integral and proportional response with a single gain For example the
43. SWITCH CONFIGURATION 5 SET SPEED MIN SET SPEED MAX Trim Mode reverse pot EXTERNAL ANALOG MODE 101 Set speed with pot EXTERNAL ANALOG MODE 002 SWITCH CONFIGURATION 1 4 SET SPEED 1 4 SET SPEED TRIM SET SPEED MIN SET SPEED MAX Set speed with pot EXTERNAL ANALOG MODE 102 Set speed with pot PTO Available EXTERNAL ANALOG MODE 012 SET SPEED MIN SET SPEED MAX Set speed with pot PTO Available EXTERNAL ANALOG MODE 112 Drive by wire no IVS EXTERNAL ANALOG MODE 003 SWITCH CONFIGURATION 1 4 SET SPEED 1 4 SET SPEED MIN SET SPEED MAX Drive by wire IVS normally closed EXTERNAL ANALOG MODE 103 Drive by wire IVS normally open EXTERNAL ANALOG MODE 203 Drive by wire no IVS EXTERNAL ANALOG MODE 013 SET SPEED MAX SET SPEED MAX Drive by wire IVS normally closed EXTERNAL ANALOG MODE 113 p gt SWITCH_CONFIGURATION 1 4 Drive by wire IVS normally open EXTERNAL_ANALOG_MODE 213 SET SPEED 1 4 SET SPEED MIN SET SPEED MAX Woodward 65 APECS 5000 Electronic Engine Speed Governing System Manual SE 4096 Step 8 Step 9 Calibrate any additional Calibrate any additional parameters if needed parameters if needed RAMP DOWN RATE PID Gains Adjustment gt RAMP UP RATE
44. Use the diagram below to connect your APECS controller to ACT your preferred speed sensor and various inputs and outputs Calibration Tool Setup RPM J1 10 Computer XO RPM UI 3 i Twisted Pair Shielded Wire shield grounded at controller only Twisted Pair Wire gt 1 twist per inch VBB2 J1 11 SP1A J1 5 A TXD J1 1 RCV J1 12 ih 4 pin mating O E Molex 39 01 2040 vw sl Sai SS AM S 7 P ES IVS J2 5 SW1 J2 7 APECS 5000 Controller AUX J2 4 12 24v output PTO J2 6 Slow Blow Fuse Power DC VBAT J19 amp EPSW J2 9 Twisted Pair Wire gt 1 twist per inch RPS J2 1 not used Figure 6 APECS 5000 Wiring Diagram Speed Sensor Input Magnetic Pikap Spark Ignition Magneto ojo Hall Effect Zu STEPPER MOTOR ACTUATOR Analog Speed Input Idle Verification used with pedal input Switched Speed Input amp Switched to VBAT Auxiliary Output Yoo D Lamp Relay PTO Switch Input Zeg Switched to VBAT Engine Protection Input i V Switched to Ground 12 Woodward APECS 5000 Electronic Engine Speed Governing System Manual SE 4096 Speed Sensor Installatio
45. al 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 Woodward 53 APECS 5000 Electronic Enqine Speed Governing System Manual SE 4096 CAUTION If you forget and set the desired speed to 1800 rpm the engine will speed up to 3600 rpm in order to reach the target Engine Start Calibration Parameters This section covers parameters for engine start calibration Autocrank On a command from an auto start switch using PTO input an engine will go through an autocrank sequence using auxiliary output This feature is useful for remote operation of certain engines or applications Caution To effectively use the autocrank feature the actuator should be able to stop the engine otherwise an ignition cutoff type system must be provided Calibration Parameters Needing Configuration 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 seconds AUTOCRANK MAX TRIES Maximum number of crank rest cycles before autocrank logic stops trying to start the engine and flags a fault Range
46. anual Help Topics This command allows you to search for specific information by displaying software menu items or through key words 1 Click on Contents for an outline of the software applications listed by menu items 2 Click on Index or Find to locate a specific topic through an alphabetical listing or by typing in a word or phrase 3 Follow the on screen commands to page through the manual About ACT This command displays the version of the calibration tool that you are currently using This information is important for tool identification purposes and for servicing support User s Manual This command accesses the User s Manual which includes comprehensive information on the APECS 5000 controller wiring diagrams ACT software menus and calibration parameters The manual may be viewed online or printed for future reference Woodward 37 APECS 5000 Electronic Engine Speed Governing System Manual SE 4096 Chapter 4 Calibrating APECS Features perser A A ee Calibration Guide This section explains the procedures for calibrating configuring and adjusting the various APECS 5000 features to work with your application Before proceeding make sure you have installed all the required hardware for your system and are familiar with using the APECS All purpose Calibration Tool ACT Safety Precautions The APECS 5000 is a user configurable engine speed governor and will follow your settings and
47. application launches 4 Ifthe Parameter View screen is already open when changes are made to the view list close the Parameter View screen and re open it to make the changes effective Save Clicking Save will prompt the user for a file name to save the currently viewed configuration to Type in a file name that reflects the purpose of the saved configuration and click Save The view configuration dialog will now display the selected file name in the title bar Choose or create a file to save the view setup to S Save in ACT da ft El engine speeds avf El error codes avf Open Clicking Open will prompt the user for a file name of a previously saved View Configuration Fiename fmyvienSeus Select the desired file and click Save as type ACT View Setup Files D avf y Cancel Open The View Configuration will be E 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 configurations by changing the configuration on the parameter list screen F9 or Open then opening a new Parameter View NOTE Only one of the parameter view screens can be monitoring the controller at once Configure Menu Configure Serial Port This
48. assignment if needed Progress Display Screen This screen is intended to inform the user of the progress of time consuming communication procedures It will close automatically when the procedure is complete Reading Calibration Values from controller Please wait RESET SPEED 2 Moving Around the Software There are five main menu items available with ACT Several options are available under each main menu item The discussion in the following pages assumes the cursor is at the main menu screen Use mouse to select or move around the menu Use left mouse to execute a command or accept a condition Use function key lt F1 gt for HELP A HOT key highlighted character in a menu item can also be used to access or activate a menu or sub menu e g File use lt ALT gt lt F gt Click on the x box in the upper right hand corner to exit ACT 22 Woodward APECS 5000 Electronic Enqine Speed Governing System Manual SE 4096 ACT Menus amp Options ACT Menu Structure The ACT has five main menus File Menu Calibrate Menu Monitor Menu Configure Menu and Help Menu with several options available under each A complete discussion of all ACT menus and options is presented in the following pages Save APECS Cal to File View CAL File Comments View Text File FILE MENU Convert APECS Cal to Text Convert Cal File to Text Convert Cal File to Strategy RE MONITOR MENU CONFIGURE MENU Configure Serial Port Help Topics
49. closed throttle position in the event of a fault condition or loss of power it is strongly recommended that the auxiliary output be configured for diagnostic shutdown to assure that the engine will shut down in the event of a fault condition A lamp or relay can be wired to the auxiliary output on the controller for a variety of purposes 1 to flash faults 2 to indicate overspeed condition 3 to indicate diagnostic shut down 4 to indicate PTO engaged 5 for autocrank output Depending on your application wire the lamp or relay according to the manufacturer s specification Once the output is wired refer to the APECS Calibration section to configure the appropriate parameters NOTE If the output draws more than 200 mA the output will be disabled and a fault code will flash APECS 5000 Vbatt AUX J2 4 or AUX 2 J2 3 Low Side Driver Figure 11 Typical Lamp Wiring APECS 5000 AUX J2 4 or AUX 2 J2 3 Low Side Driver Figure 12 Typical Relay Wiring 18 Woodward O A APECS 5000 Electronic Engine Speed Governing System Manual SE 409 Autocrank Wiring The APECS 5000 offers an autocrank feature for APEGSSUBA pros remote or automatic starting of certain engines Auto Start Switch and applications Wire the crank motor relay on the engine to the d 4 controller auxiliary output low side driver Wire AUX 324 1 the auto start rocker toggle switch to the Reese SRAN
50. commands immediately Please be aware of this when calibrating and entering values in the unit It is possible to enter values in the APECS unit that are in excess of what the engine is capable of performing and outside of safe operating range It is the user s responsibility to be accurate when entering data into the APECS or the ACT Entering values outside of safe operating range can result in serious physical injury and or damage to the equipment or application WARNING An overspeed shutdown device independent of the APECS system should be provided to prevent loss of engine control that may cause personal injury or equipment damage Calibration Categories To incorporate any of the programmable features in your system a set of parameters associated with each feature must be calibrated using the calibration tool ACT These parameters are grouped under various categories under the Calibrate Menu in ACT Refer to Table 3 below Table 2 Calibration Categories and Features CALIBRATION CATEGORY FEATURES AVAILABLE Governor Gain PID Gain Settings Engine Set Speed External Pot Calibration Speed Input Speed Input Calibration Overspeed Underspeed Actuator Output Stepper motor direction max travel and step rate NOTE For basic APECS operation to begin you only need to configure Engine Set Speed Speed Input and Actuator Output parameters All other parameters are preset to values that will work with many applications
51. ctuator APECS Advanced Proportional Engine Control System Engine governing system developed by Woodward APP Analog Pedal Position An analog input with voltage proportional to the desired engine speed Autocrank An APECS feature that allows remote or automatic starting of the engine Cal File File containing APECS calibration data Cal Tool Version The version of calibration tool software in use Calibration Process of configuring and adjusting the controller to work with a specific application Calibration Wizard Interactive software guide to help you set up basic calibration and get the controller in operation quickly Control Strategy The version of software residing in the controller Duty Cycle Percentage of time a pulse width modulated pwm signal remains on Parameter Numerical value that helps the user calibrate the APECS controller PTO Power Take off An APECS feature that allows selection between pedal input and speed switch PWM Pulse Width Modulation Means of simulating analog output with a digital device The PWM duty cycle determines the equivalent analog output the higher the duty cycle the higher the equivalent analog output Speed Sensor Device such as a magnetic pickup that senses engine speed Stepper Motor An electro mechanical rotary actuator that moves in discrete steps Stepper motors are small in size high in torque and low in current draw Woodward 67 APECS 5000 Electronic Engi
52. d Setpoint Input Yes Switched Speed Setpoint Inputs Yes See Engine Speed Select Options table below To incorporate any of these features in your system refer to Installing the Hardware to install the selected feature and Calibrating APECS Features to configure the feature for your application Woodward 7 APECS 5000 Electronic Engine Speed Governing System Manual SE 4096 Engine Speed Select Option Table The following speed select options are available with the APECS 5000 SPEED SELECT OPTIONS NO ANALOG INPUT Use a speed switch to select up to 4 discrete speeds or use a momentary switch to manually increase or decrease speed at preset rates SPEED TRIM Speed ee Use a speed pot analog input to trim Stitch the speed switch selected set speed L SET SPEED WITH POT Speed Pot Use a speed pot analog input to adjust set speed SET SPEED WITH POT OR SPEED SWITCH Use a speed pot analog input to adjust the set speed or use a speed switch to select up to 4 discrete speeds Use the PTO switch to select between speed pot and speed switches DRIVE BY WIRE Use pedal pot analog input to adjust set speed Can be used with or without IVS Includes safety startup logic to assure engine always starts at idle DRIVE BY WIRE OR SPEED SWITCH Use a pedal pot analog input to adjust the set speed or use a speed switch to select up to 4 discrete speeds Can be used with or without IVS Use the
53. e first speed commanded is selected by the speed switches Can command the engine to stop without powering down APECS Yes if you are using 2 3 or 4 speed mode Simply set one of the set speeds to 1 When you select that speed with the switch the engine will follow the command to 1 Usually powering off the APECS unit shuts down the engine and the throttle is immediately closed However if you command a shutdown with the switch and the ramp down rate is set low the engine will be stopped in a soft shutdown manner When the engine starts does the desired engine speed jump right to the initial speed command No For a smoother start desired engine speed ramps to the initial speed command from SET SPEED MIN SET SPEED MIN is independent from the other 4 set speeds It may be set to any value above or below the other speeds The recommended value for SET SPEED MIN is the low idle speed of the engine Remember that SET SPEED MIN is also the minimum variable speed commanded when lowering engine speed with the toggle switch Speed Input Configuration Parameters Calibration Procedures SPEED TYPE electrically configures the input circuitry for the speed input type and also specifies how electrical noise is to be detected and rejected PULSES PER UPDATE and PULSES PER REV are factory set to prevent the unit from calculating an engine speed and driving the actuator These two parameters must be calibrated to a non zero value befor
54. e negative side of the coil primary winding e Magneto spark ignition Speed can be sensed from the spark kill wire on the primary winding but will not work if a diode is placed between the magneto and the APECS input may be found on some multi cylinder engines with magneto ignitions e Hall Effect sensor The speed input may not work with certain types of speed input such as the Ford TFl system that vary the charging voltage to the coil Stepper Motor Actuator Stepper motors provide a compact low current high torque means of throttle actuation on small engines Unlike a proportional solenoid which traverses its full range of travel by increasing the current of a single high current winding a bi polar stepper motor has two low current windings and is moved by alternating the current and current polarity in the two windings Woodward stepper motors move by rotating in steps of 1 8 degrees The degrees rotated the speed of rotation and the direction of rotation are easily controlled using pulsed signals from the controller Figure 2 Woodward Stepper Motor Actuator for APECS 5000 Controllers Woodward 3 APECS 5000 Electronic Engine Speed Governing System Manual SE 4096 The sequence for pulsing the coils is shown in the table at left To move the stepper motor shaft in a counter clockwise direction follow the step sequence from 1 through 4 then repeat until the Oo 9 desired position is 99 reached T
55. e normal APECS operation can begin Calibration Parameters Needing Configuration SPEED TYPE Factory set for a mag pickup This parameter electrically configures the input circuitry for the speed input type and also specifies how electrical noise is to be detected and rejected Recommended values are as follows Mag Pickup 128 Coil Ignition 2 Magneto Ignition 3 Hall Effect Sensor 131 PULSES PER UPDATE The number of pulses received by the controller between engine speed calculations and updates 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 set to zero Must be non zero to operate 52 Woodward APECS 5000 Electronic Enqine Speed Governing System Manual SE 4096 PULSES PER REV The number of teeth on the engine speed pickup wheel mag pickup input and Hall Effect sensor or the number of spark pulses per engine rev ignition input To figure out the pulses per revolution you must determine the kind of speed signal input 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
56. ectable overspeed and underspeed parameters that affect engine shutdown Calibration Parameters Needing Configuration OVERSPEED_RPM Critical engine speed used for overspeed protection rpm Set OVERSPEED_RPM to zero if overspeed protection is not desired Normal closed loop governing will decrease the duty cycle to the actuator any time engine speed is above the set point Overspeed protection immediately shuts off the actuator when an overspeed condition is detected Engine speed must be brought back to zero before the actuator is driven again Setting OVERSPEED_RPM to zero disables the overspeed protection feature Default value 0 UNDERSPEED_RPM Minimum engine speed used for underspeed shutdown rpm Normal closed loop governing will increase the duty cycle to the actuator any time engine speed is below the set point Underspeed shutdown immediately shuts off the actuator when an underspeed condition is detected Engine speed must be brought back to zero before the actuator is driven again Setting UNDERSPEED_RPM to zero disables the underspeed protection feature 56 Woodward APECS 5000 Electronic Engine Speed Governing System Manual SE 4096 UNDERSPEED RUN TIME Amount of time the engine must be in run mode before underspeed shut down is activated seconds Calibration Procedures The overspeed protection feature immediately shuts off the actuator when the engine runs above OVERSPEED RPM Setting the OVERSPEED RPM va
57. effective proportional gain used is PROPORTIONAL_GAIN X MASTER_GAIN This permits adjusting all three gains with a single calibration parameter Range 0 255 Default value 1 0 PID Gain Settings Response Plots ACT allows the user to adjust the P l and D gain settings and observe the response directly on screen in the form of a real time plot The plots on the following page illustrate the various conditions a user may encounter while tuning an application Although conditions may vary according to application and nature of load these plots are typical of what is often observed Figures 16 20 illustrate less desirable conditions often encountered while tuning an application and suggest probable causes Figure 21 shows a plot of a properly tuned application Although conditions may vary according to application and nature of load this plot is typical of what is often desired 44 Woodward APECS 5000 Electronic Enqine Speed Governing System Manual SE 4096 Desired RPM A Desired RPM Actual RPM F TIME Figure 17 PID Gains Too High Actual RPM Actual RPM F Desired RPM J Figure 18 Integral Gains Too Low Figure 19 Derivative Gains Too High Desired RPM K Remove Load Actual RPM F Add Load Figure 20 Integral Gains Too High or Figure 21 Desirable Response Derivative Gains Too Low NOTE Excessive friction and slop in the linkage are primary contributors to poor governor stability If it is
58. en read back with the result placed in the APECS Value field 5 Press lt Esc gt to exit Download Cal File to APECS The Download Cal File to APECS command allows you to download the entire calibration set from a file to the APECS permanent memory This is a convenient one step method for e Reverting back to a known good calibration set after experimenting with new calibration settings e Programming multiple APECS units for a particular application The downloaded file may have been previously configured and calibrated for satisfactory engine performance with another APECS unit To Download a Cal File to APECS Choose a Calibration file to download 21x 1 Choose Calibrate gt Download Lookin T Desktop eE Cal File to APECS The following screen allows you to select a Cal file to download pen Files of type ca Files 000 4CT y Cancel T Open as read only Calibration File Comments 2 Choose a file and Processing Calibration Values click OK The fol lowing screen will EET show the progress 28 Woodward APECS 5000 Electronic Engine Speed Governing System Manual SE 4096 3 The following screen is shown when the operation is complete ACT x AN The calibration File was downloaded successfully NOTE During the Download Cal File to APECS operation the user may encounter a situation where the Cal File password is different from that of the APEC
59. engine is not allowed to start up in PTO mode PTO is locked out until the engine has started and the PTO switch is transitioned from its off position Set Speed Calibration FAQ After a power down power up reset does APECS remember the last speed it was using No The only data APECS retains after power down are the calibration parameter settings If you are using the variable speed mode you will have to reestablish the desired speed after the engine is restarted However if you are configured for one of the four set soeed modes then APECS will command the same speed on the next power up after an optional warm up period as long as the switches haven t been changed If using variable speed mode what is the initial soeed command when the engine starts SET SPEED WARMUP Even if WARMUP TIME is set to 0 this will be the initial engine speed command It does not change until the engine is running and the toggle switch is pressed The toggle switch has no effect when the engine is not running Woodward 51 APECS 5000 Electronic Enqine Speed Governing System Manual SE 4096 If using the 4 speed modes what is the initial speed command when the engine starts That depends on your use of a warm up speed lf you re using a warm up speed enabled by setting WARMUP_TIME to a non zero value then the first speed commanded will be SET SPEED WARMUP If you are not using a warm up speed disabled by setting WARMUP TIME to zero then th
60. ep track of specific engine application and environment data associated with the file 4 ACT will save the calibration set and automatically append the file extension ACT to the file name Calibrating an APECS Unit with a Saved Calibration File You may wish to calibrate additional APECS units with a saved calibration file for consistent optimized operation To Calibrate an APECS Unit with a Saved Calibration File 1 Access the Calibrate menu to activate the Download Cal File to APECS command 2 Select the appropriate file to download refer to the comment list on the right side of the screen to help identify the desired file Enter password if prompted ACT will download file calibration to APECS permanent memory 3 Repeat Steps 1 and 2 if multiple APECS units are to be calibrated NOTE The APECS unit must be powered up but need not be mounted on the engine to carry out the calibration procedure Understanding APECS Calibration Parameters This section provides answers to frequently asked questions about calibration parameters lists parameters and provides calibration procedures Frequently Asked Questions What is a calibration parameter A parameter is a numerical value that helps the calibrator adjust or set the APECS controller Once fixed by a calibrator the parameter is not subject to change while the system is operating APECS calibration parameters are used not only to adjust and set the controller bu
61. from the controller is used to update the screen Data received between timer ticks is discarded 34 Woodward APECS 5000 Electronic Engine Speed Governing System Manual SE 4096 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 Calibration Wizard will automatically set up the plots if there are no saved defaults Display Faults This command allows you to display present faults in real time This means if new faults occur while you are monitoring the screen will automatically update to display the current faults The display will also show historical fault codes that have been previously logged but do not currently exist Historical fault codes are helpful when tracking down intermittent faults To Display Faults in Real Time Current Faults Start fault_flags1 1 User has not calibrated APECS unit h M D gt D a EE fault_flags1 4 actuator disconnected or short circuit fault_flags1 5 Fact ttings lost 1 e C O O S e O n Ito r l S p ay PTER 6 Ks AM D fault_flags1 7 gain set pot out of range Fau Its fro m th e m al n m e n u fault_flags2 9 battery voltage out of range fault_flags2 10 dummy 2 1 fault H H kb fault_flags2 11 dummy 2 2 fault The application will launch the Fault view Historical Faults No Historical Faults The application will update the Clear Historical Fa
62. g materials when returning a complete control protective caps on any connectors antistatic protective bags on all electronic modules packing materials that will not damage the surface of the unit at least 100 mm 4 inches of tightly packed industry approved packing material a packing carton with double walls a strong tape around the outside of the carton for increased strength Woodward 69 APECS 5000 Electronic Engine Speed Governing System Manual SE 4096 Return Authorization Number When returning equipment to Woodward please telephone and ask for the Customer Service Department 1 800 523 2831 in North America or 1 970 482 5811 They will help expedite the processing of your order through our distributors or local service facility To expedite the repair process contact Woodward in advance to obtain a Return Authorization Number and arrange for issue of a purchase order for the item s to be repaired No work can be started until a purchase order is received NOTE We highly recommend that you make arrangement in advance for return shipments Contact a Woodward customer service representative at 1 800 523 2831 in North America or 1 970 482 5811 for instructions and for a Return Authorization Number 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 wh
63. g the PID gains directly from the Plot Display screen To Make PID Gain Adjustments from Plot Display Screen 1 Press the letter lt P gt for proportional lt l gt for integral or lt D gt for derivative gain adjustment The application will enable the gain you selected 2 Use the Up or Down arrow keys to increase or decrease the present value The arrow keys adjust the values by 0 004 New values may be typed in directly Hit lt Enter gt after you type in a value The application will save the new value in the APECS unit 3 Press the lt Esc gt to deselect the gain adjustments To Change Plot Setup This allows you to choose engine rpm desired engine speed duty cycle or any other parameter for viewing real time plots on screen Axis scales can also be adjusted to fit the parameter and or speed 1 On the Parameter Plot screen click on Configure The application will show the following screen with the current values Plot Setup E xi Plot 1 Plot 2 pi m n des zu new Ans Mas Asis Max Axis Min Axis Min x Avie Time Scale DU sec se Avis Sample Rate 100 m sec e Plot 1 Plot 2 Use the pull down to select the desired parameter to plot Axis Min Max Enter the minimum maximum value for the parameter value X Axis Time Scale Controls how much data is displayed on the X axis This value may automatically adjust for screen resolution X Axis Sample Rate Controls how often the data
64. ibrate menu Please see Change APECS Password command for more information on password protection Woodward 29 APECS 5000 Electronic Engine Speed Governing System Manual SE 4096 Compare APECS Cal to File Cal This command lets you check the differences in calibration sets between a saved file and the APECS unit The feature is useful for example to ensure that the saved file matches the calibration in the APECS unit To Compare APECS Cal to File Cal 21x Look in E Desktop y a et ES 1 Choose File gt Compare APECS E y Computer Cal to File Cal This screen allows you to select a Cal File to com pare JEF Pdf s File name Open Files of type Cal Files 0D0 4 CT y Cancel I Open as read only Calibration File Comments 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 ACT x message box will list the compare results If the parameters in the file match the controller the AN Er EE following message box appears 4 Click OK to close If there were mismatches the following message will appear Compare Differences x Controller lt gt C WOODWARDNACT TOOL APX41MOSTEST ACT Mismatch List Name File Controller Units ACTUATOR_FDBK_GAIN 0 20001 0 72498 NONE ACT FDBK KFILT 0 801 0 977 NONE AFB LOST DLY 21 20 ms 10 AFB NO AMPS 33000 D m APP AD ORH 254 1
65. ich is also on the nameplate How to Contact Woodward In North America use the following address when shipping or corresponding Woodward Governor Company PO Box 1519 1000 East Drake Rd Fort Collins CO 80522 1519 USA Telephone 1 970 482 5811 24 hours a day Toll free Phone in North America 1 800 523 2831 Fax 1 970 498 3058 For assistance outside North America call one of the following international Woodward facilities to obtain the address and phone number of the facility nearest your location where you will be able to get information and service Facility Phone Number Brazil 55 19 3708 4800 India 91 129 230 7111 Japan 81 476 93 4661 The Netherlands 31 23 5661111 You can also contact the Woodward Customer Service Department or consult our worldwide directory on Woodward s website www woodward com for the name of your nearest Woodward distributor or service facility For worldwide directory information go to www woodward com ic locations 70 Woodward APECS 5000 Electronic Enqine Speed Governing System Manual SE 4096 Engineering Services Woodward Industrial Controls Engineering Services offers the following after sales support for Woodward products For these services you can contact us by telephone by email or through the Woodward website e Technical Support e Product Training e Field Service Contact information Telephone 1 847 967 7730 Fax 1 847 967 7832 E mail info_
66. ile 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 26 Woodward APECS 5000 Electronic Engine Speed Governing System Manual SE 4096 ACT will read all of the calibration values from the controller create and save a text file with the parameter names values and units then display the file using the default text viewer Convert Cal File to Strategy This command is used to convert old ACT files for use with controllers that have a different control strategy version ACT will 1 Parse through all of the calibration parameters in the old ACT file 2 Search for the same calibration parameters in the new ACT file and assign values from the old calibration To Convert a Cal File to a New Strategy Choose File gt Convert Cal File to Strategy 2 ACT will prompt you to enter a name to save the text file Enter a file and click OK ACT will read all of the calibration values from the controller create and save a text file with the parameter names values and units then display the file using the default text viewer 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 These commands can be
67. ill always prompt you to enter the new password to gain access to these features You only need to enter the password once during any session to gain access to all password protected features APECS Calibration Wizard The APECS Calibration Wizard is an interactive guide to help you get your controller unit up and running as quickly as possible To Calibrate a Controller Unit Using the APECS Calibration Wizard 1 Choose Calibrate gt Calibration Wizard 2 The Wizard will give you the option to use the default calibration or modify the existing one If you select the default calibration the Wizard will reset all calibration parameters 3 Press lt Enter gt to continue or lt Esc gt to abort the Wizard If you press lt Enter gt the Wizard will lead you through the calibration process with a series of questions When all questions have been an swered the Wizard will ask you to confirm that the values entered are accurate 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 APECS Wizard will download the new calibration and reset all APECS parameters This will complete the APECS Wizard operation NOTE The APECS Calibration Wizard only covers basic calibration It does not automatically assure optimum engine operation Please refer to APECS Calibration Procedures for more information 5 You are now ready to run your e
68. ings Response Plots ooooccncccccocncnncccnancnnncnonancnnnnnnnnnconnnnnnns 44 Engine Set Speed Calibration Parameters rrrrrrnrnnnrrvvnrnnnvrrvvnrnnnrrrernrrnnerreennnnn 45 Calibration dee TEE 45 External Analog Input Calibration with IW 47 SWilerCGontiqgura ton ModE S a a bo eed 49 Extemal Rot Calbra te WEE 50 leede Nee EE 50 PIO AU taa 51 Calibration Pro cedui s avse see 51 Set Speed Calibration FACE 51 Speed Input Configuration Parameters oocccccccccnccnnnconnnnnononononnnnncnonannnnnononanenonoos 52 Calibration Procedures ecann a eE a E E 52 PULSES PER REV FAG EE 53 Engine Start Calibration Parameters cccccccconncnncccnnnncnncncnnnncnnnnnnnnnnnnnnonannnnncnnnnns 54 AUO seer 54 ENGINE ele secaraa aT riera 54 Diagnostics Calibration Parameters ooooccccccccncccnnccononncnncnononnnononononncnnonononnnnnononans 55 Engine Protection Input 55 Overspeed Underspeed PDrotecthon 56 Overspeca FAO ana a ds DO do 57 Actuator Output Calibration Parameters nnn000nnnnannnnnannnnnnnnnnnnnnnnnrnnnnnennnnnnene 58 Stepper Motor COMMOWKAIOM es it ti 58 A ONE 59 Droop Led E 60 CHAPTER 5 TROUBLESHOOTING snanvnnnnnnnnnannnennnnnnnnannnnnnnannnnannnennnnnnennannnnnen 61 Troubleshooting Guidelines cccccssseecceccceseeeeeceeeeseeeeseeeeeeeesseeeeeesesaageeeeseaas 61 FAE 0 esea e E 61 Calibration Setup amp Configuration Parameters Flowchart rrnnrrrnrnnrnonrnnnnrnnnnn 63 Glossary
69. iome ter Display parameters app_norm and step Move the pot to evaluate stepper motor range and direction of travel As app_norm varies between 0 and 1 step 58 Woodward APECS 5000 Electronic Enqine Speed Governing System Manual SE 4096 should vary between 0 and STEP MAX STEPS When step equals 0 the ac tuator should be at closed throttle position If not change the value of the most significant bit of STEP CONFIG the direction bit being careful to leave the two least significant bits equal to 1 Adjust STEP MAX STEPS to achieve full travel When done set STEP MODE 0 4 Ifa potentiometric input is not available set STEP MODE 2 and STEP CAL 0 The actuator should move to the closed throttle position If not change the value of the most significant bit of STEP CONFIG the direction bit being careful to leave the two least significant bits equal to 1 After changing STEP CONFIG cycle power to the APECS 5000 controller and the stepper motor should move to the closed position Set STEP CAL STEP MAX STEPS and the actuator should move to the fully open position If not adjust both STEP CAL and STEP MAX STEPS When done set STEP MODE 0 If desired the stepper motor can be configured to cycle continuously between closed and open by setting STEP MODE 3 When doing this look for lost steps It may be necessary to adjust STEP PRD or STEP WAIT to prevent lost steps Note reducing the step rate does not always eliminate
70. le the engine may be capable of performing at the rated rom the generator or pump is likely to have a lower rpm rating than the engine Furthermore there are certain parameters that are used to properly configure an application Entering incorrect values for these parameters will result in improper configuration and may make the engine run at maximum throttle Entering values outside of safe operating range can result in serious physical injury and or damage to the equipment List of Parameters CATEGORY PARAMETER DESCRIPTION eal DERIVATIVE GAIN Speed stability Governor INTEGRAL GAIN Steady state speed Gain caiginn PROPORTIONAL GAIN Combined PID gain response AAA A Engine Set Delay for return to Speed Ge idle mode 023 le Calibration EXTERNAL ANALOG MODE External analog o input configuration RAMP_DOWN RATE E speed ramp 1000 own rate MASTER_GAIN RAMP UP RATE Engine speed ramp 1000 up rate increment speed decrement speed SET_SPEED_TRIM Engine trim speed 200 gt rpm speed Multi speed SPEED DECREASE DELAY decrease delay time sec Woodward 41 APECS 5000 Electronic Engine Speed Governing System Manual SE 409 CATEGORY PARAMETER DESCRIPTION j D 1 2 3 4 multispeed SWITCH_CONFIGURATION e 1 WARM_UP_TIME Ms alla warm up speed Mag pickup 128 SPEED TYPE Gall Ignition g 128 Magneto 3 Hall Effect 131 Speed Input Configuration PULSES PER REV No of pulses per engine revolution
71. lignments in both shaft angle and shaft offset and contributes to accurate stable and responsive performance Either a commercially available shaft coupling may be used or a simple linkage STEPPER fabricated using two levers and a lightweight link A light return spring on the throttle will eliminate backlash in the linkage Any binding in the linkage will detract from performance and may prevent the governor from working FIGURE 5 Connecting Stepper Motor to Throttle Programmable Features The APECS 5000 expands Woodward s line of programmable engine governors to address the needs of the mobile equipment industry Enhanced input and output capability combined with a flexible configuration permits the controller to easily adapt to a wide variety of engine governing applications Following is a list of features available with the APECS 5000 e Analog Speed Setpoint Input suitable for use with a potentiometer or an accelerator pedal position sensor idle verification available e Autocrank useful for remote operation of engines using an auxiliary output e Auxiliary Output Drives a lamp or relay e Droop Governing allows non isochronous speed governing e Engine Protection Input protects against adverse conditions such as loss of engine oil pressure or excessive coolant temperature e Engine Start Calibration useful for applications that require special startup operation e g warm up speed reduced governor gains missing speed
72. lost steps sometimes increasing the step rate will improve performance In general increased inertia of the throttle mechanism will detract from stepper motor performance Auxiliary Output The auxiliary output feature is a multipurpose output that can drive a lamp or a relay See wiring information in Chapter 2 Because a stepper motor failure can cause a runaway engine condition it is strongly recommended that the auxiliary ouput be configured as an engine shutdown AUXILIARY OUTPUT MODE 2 Calibration Parameters Needing Configuration AUX_OUTPUT_RPM When AUXILIARY_OUTPUT_MODE 1 APECS 5000 turns on the auxiliary output when engine rpm exceeds this speed The auxiliary output turns back off if engine speed falls 20 rpm below AUX OUTPUT RPM AUXILIARY OUTPUT MODE This parameter is used to let the software know how the auxiliary output of APECS 5000 is to be configured Calibration Procedures Set the AUXILIARY OUTPUT MODE value to the settings below to achieve a target configuration for a certain APECS 5000 engine system setup VALUE AUXILIARY OUTPUT RESULT No output ON when engine speed is above AUX_OUTPUT_RPM ON when there is an active diagnostic shutdown condition use with auxiliary shutdown device ON when PTO is engaged use with PTO indicator lamp Autocrank output use to drive engine crank motor relay Mimics on board LED ON when engine speed present flashes faults Woodward 59 APECS 50000 Elect
73. lue to zero disables this feature The underspeed protection feature immediately shuts off the actuator when the engine rom runs under the UNDERSPEED RPM value Set the UNDERSPEED RUN TIME value as desired Setting the UNDERSPEED RPM value to zero disables the underspeed protection feature When an engine overspeed underspeed condition is detected the engine protection control logic causes 1 the actuator duty cycle to go immediately to zero 2 a fault code activation which is signified by LED flashing After engine protection control logic tripping the fault code will continue to flash the LED This signifies to the user that the engine stopped due to overspeed or underspeed engine conditions The engine may later be restarted without resetting the unit this action will cause the fault code to reset and the LED will then stop flashing Overspeed FAQ How Does Overspeed Work The APECS 5000 has the diagnostic capability to detect and react to an overspeed condition The feature uses two programmable parameters OVERSPEED RPM and OVERSPEED TIME Overspeed feature immediately shuts off the actuator when the engine runs above OVERSPEED RPM for OVERSPEED TIME OVERSPEED TIME is used to adjust the sensitivity A large value will delay the shut down and a small value will hasten it A value as small as zero can be used which means that the first occurrence of engine speed being over OVERSPEED RPM will result in a shut down This is too sensiti
74. n Guidelines There are four different speed sensing devices that can be used with the APECS 5000 system e Magnetic pickup e Spark ignition e Magneto e Hall Effect Sensor Refer to Table 1 Controller Wiring and Figure 6 Wiring Diagram for guidance in selecting the speed sensor suitable for your controller and application For magnetic pickups and Hall Effect sensors the mounting of the sensor unit must be rigid excessive vibration can cause erroneous signals and unreliable performance Use twisted pair shielded wire for all speed apecs sono sensor wiring Shield should be grounded RPM J1 10 at the controller only Figure 7 Speed Sensor Wiring Speed Sensor Wiring Magnetic Pickup Installed opposite an engine driven gear such as the flywheel it transmits a signal each time the magnetic flux path across the pole is interrupted by a gear tooth Connect Pin J1 10 to the positive and Pin J1 3 to the negative side of the sensor Most sensors do not have a positive or negative side and can be connected either way Spark Ignition Intended for either traditional coil and distributor ignition or distributorless ignition systems Traditional coil and distributor ignition 2 3 4 6 and 8 cylinder engines Connect Pin J1 10 to the negative side of one coil primary Distributorless ignition 2 4 6 and 8 cylinder engines Connect Pin J1 1
75. n ACT file that cannot be viewed or printed directly Viewing and printing must be done from a converted text file There are two convert commands available with ACT Convert APECS Cal to Text and Convert Cal File to Text The difference between the two commands is as follows 1 In Convert APECS Cal to Text operation the calibration set that is converted is from the APECS unit 2 In Convert Cal File to Text operation the calibration set that is converted is from a previously saved file You may use the View Text File command to view text files Convert APECS Cal to Text This command allows you to create a text file of APECS calibration data for viewing or printing from any text editor utility in Windows A printed copy of the calibration data can be useful for future reference To Convert APECS Calibration to Text 1 Choose File gt Convert APECS Cal to Text 2 ACT will prompt you to enter a name to save the text file Enter a file and click OK ACT will read all of the calibration values from the controller create and save a text file with the parameter names values and units then display the file using the default text viewer Convert Cal File to Text This command allows you to convert a previously saved ACT calibration file to a text file for viewing or printing from any text editor utility in Windows A printed copy of the calibration data can be useful for future reference To Convert Cal F
76. ne Speed Governing System Manual SE 4096 Chapter 6 Service Options AAA E Product Service Options The following factory options are available for servicing Woodward equipment based on the standard Woodward Product and Service Warranty 5 01 1205 that is in effect at the time the product is purchased from Woodward or the service is performed e Replacement Exchange 24 hour service e Flat Rate Repair e Flat Rate Remanufacture If you are experiencing problems with installation or unsatisfactory performance of an installed system the following options are available e Consult the troubleshooting guide in the manual e Contact Woodward technical assistance see How to Contact Woodward later in this chapter and discuss your problem In most cases your problem can be resolved over the phone If not you can select which course of action you wish to pursue based on the available services listed in this section Replacement Exchange Replacement Exchange is a premium program designed for the user who is in need of immediate service It allows you to request and receive a like new replacement unit in minimum time usually within 24 hours of the request providing a suitable unit is available at the time of the request thereby 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
77. ne is not running Setting ENGINE PRTCT RUN TIME to 8000 or more will disable the engine protection option ENGINE PROTECT TIME The amount of time spent with the engine protection input made before the actuator is shut down msec The APECS 5000 has a dedicated engine protection switch input The engine protection feature must be enabled by setting ENGINE_PRTCT_RUN_TIME to a value less than 8000 Once the engine has been in run mode longer than ENGINE_PRTCT_RUN_TIME if the engine protection input is grounded for longer than ENGINE_PROTECT_TIME milliseconds the governor will go into shutdown mode and the fault lamp will flash a four code Calibration Procedures ENGINE PRTCT RUN TIME is set to the time in seconds the engine must be running before a grounded signal on the engine protection input will be serviced If ENGINE PRTCT RUN TIME is set to 0 then the input will also inhibit any actuator duty cycle at cranking if the engine protection switch contacts are closed The input must be made before engine shutdown actuator output will begin If the engine has been running longer than ENGINE_PRTCT_RUN_TIME and the engine protection input has been made continually not intermittently then the actuator will be shutdown and a fault will be generated The lamp on the APECS unit will flash to indicate the fault and the fault will be cleared when the engine is restarted Overspeed Underspeed Protection This feature incorporates user sel
78. ngine Press any key to go directly to the Parameter Plot screen where you can adjust the PID gains 32 Woodward APECS 5000 Electronic Enqine Speed Governing System Manual SE 4096 Monitor Menu The Monitor Menu allows you to observe engine and APECS operation in real time The following commands are available under the Monitor Menu e Parameter View e Parameter Plot e Display Faults e Control Strategy e 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 engine I 399 4 1 launch the view screen Sc eg ver NONE 2 The screen automatically Cone starts reading values from the controller and displaying the values 3 To stop the updating click on Stop The button name will then change to Start Clicking it again will start updating again NOTE If any other screen is opened that requires communication with the controller while the screen is updating the Parameter View screen will be automatically stopped 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
79. niles woodward com Website www woodward com ic Technical Support is available through our many worldwide locations or our authorized distributors depending upon the product This service can assist you with technical questions or problem solving during normal business hours Emergency assistance is also available during non business hours by phoning our toll free number and stating the urgency of your problem For technical support please contact us via telephone email us or use our website and reference Customer Services and then Technical Support Product Training is available at many of our worldwide locations standard classes We also offer customized classes which can be tailored to your needs and can be held at one of our locations or at your site This training conducted by experienced personnel will assure that you will be able to maintain system reliability and availability For information concerning training please contact us via telephone email us or use our website and reference Customer Services and then Product Training Field Service engineering on site support is available depending on the product and location from one of our many worldwide locations or from one of our authorized distributors The field engineers are experienced 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
80. nnector 1062 20 0122 Wedgelocks 1 per connector WM 12S Blank Pins to fill empty pins 0413 204 2005 Always use an appropriate crimping tool for attaching the pins to the wiring harness Pay close attention to the pin numbers embossed on each connector 1 Refer to Figure 5 and Table 1 to install the system and subcomponents 2 Mount the unit in a location where the effects of vibration and temperature are within the specified range Operating temperature 40 F to 185 F 40 C to 85 C vibration 6 G s from 40 to 2000 Hz See Figure 5 for controller dimensions Woodward 9 APECS 5000 Electronic Engine Speed Governing System Manual SE 4096 3 Power leads are to be connected directly to a switched power source i e battery Use of a 4 amp slow blow fuse is recommended in the battery positive wire 4 When operating in a high field strength environment use shielded cable for external speed signal source Shields should be connected to the battery ground wire at one end only Use of twisted pair for battery power and actuator wiring may also increase immunity 5 Use of convoluted tubing conduit or other wire shielding is recommended to minimize the likelihood of mechanical damage to wires Avoid routing wires near sharp edges or near locations that can cause the wires to be pinched or damaged 6 Woodward recommends the use of 18 AWG 1 00mm wire for all connections This will assure a good combina
81. not possible to stabilize engine performance check smoothness of the linkage Engine Set Speed Calibration Parameters Calibration Procedures The APECS 5000 has two primary means of selecting engine speed setpoint e Using analog speed setpoint EXTERNAL ANALOG MODE e Using switched speed setpoint SWITCH CONFIGURATION To make the controller suitable for many mobile and stationary applications there are a variety of ways the speed switches and the speed pot can be configured e g independently or together Calibration Parameters Needing Configuration The two primary parameters are Woodward 45 APECS 5000 Electronic Engine Speed Governing System Manual SE 4096 EXTERNAL_ANALOG_MODE This is the main parameter that defines how the analog APP input is interpreted for selecting desired engine set speed Speed selection may be based on the analog input the speed select switches or a combination of the two See Table 4 External Analog Input Modes SWITCH_CONFIGURATION This parameter is used to let the software know how the user has configured the speed switch inputs Calibrate SWITCH_CONFIGURATION according to the selected speed mode There are five switch configurations available Single Speed Two Speed Three Speed Four Speed and Variable Speed See Table4 Switch Configuration Modes Parameters Used with the Two Primary Parameters BRAKE DELAY When external analog mode is set to 23 this parameter is used
82. o move the 33 stepper motor shaft in the D clockwise direction D O follow the step sequence from 4 through 1 then repeat until the desired position is reached Steps of less than 1 8 degrees can be obtained through a process called microstepping whereby the current levels are altered without changing the direction of current flow APECS 5000 is capable of one eighth step resolution which translates to 0 225 degrees It is possible for a stepper motor to lose steps when a resistive torque higher than the stepper torque is encountered or bumping the throttle by hand When this happens the stepper motor will skip to the nearest step with the same coil polarity which will be some multiple of four steps away from the desired position Unlike a proportional solenoid the stepper motor does not automatically return to the desired position when the resistive torque is removed but remains in its last position The APECS 5000 controller has logic to detect and recover from lost steps If the stepper motor is pulsed faster than it can respond it may lose steps Each step is a complex interaction of position velocity torque and inertia For a stepper motor at rest and receiving a one step command the rotor will accelerate from rest and actually pass the desired position before settling to the desired position Motion is typically underdamped and several oscillations will occur If a second step command occurs while the rotor is
83. of Technical Tes e 67 li Woodward APECS 5000 Electronic Enqine Speed Governing System Manual SE 4096 CHAPTER 6 SERVICE OPTIONS sa gege 68 Produc SEICE OPHION Seen a a ea 68 Heplacement Evchange 68 Fat Rate Relata 69 Flat Rate Remanttaciiu sa 69 Returning Equipment for Repair ccoooccncccocconcccncnncocononcnonnconononcnnnnnannnnonannnnononns 69 o A 69 Return Authorization Number 70 RE JE CS Eeg E 70 Howto CGONtact NWIOMAN RR 70 Engineering ServiC8S cccccccoonccnncccnonconncnnnnnnonnnononncnnononnnnnnnnnnnnnrnnnnnonanrnnnnnnnnnnnnnnnnnns 71 Technical ASSISTANCE a 72 Woodward iii APECS 5000 Electronic Engine Speed Governing System Manual SE 4096 Chapter 1 Understanding the System A A ES EE System Basics The APECS Advanced Proportional Engine Control System product line manufactured by Woodward provides a family of electronic controllers and actuators intended for use as speed governors on a wide range of diesel and spark ignition engines The controllers are microprocessor based modules and will maintain desired engine speed despite changes in engine load Governors are found on a variety of engine driven products both stationary and mobile such as generators hydraulic pumps compressors and utility vehicles Electronic engine governors work by electronically sensing engine speed comparing the actual engine speed to the desired speed commanded by the operator and adjusting the command to an actuat
84. onfigure stepper motor Speed Type mag pickup 128 Coil Ignition 2 Magneto Ignition 3 Hall Effect 131 Y Direction STEP_CONFIG Travel STEP_MAX_STEP Timing STEP_PRD STEP_WAIT Speed Input Configuration PULSES_PER_REV PULSES_PER_UPDATE These two parameters must be calibrated to a non zero value before normal APECS operation can begin The APECS 5000 is a user configurable engine speed governor and will follow your settings and commands immediately It is possible to enter values in the APECS module 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 pay attention when entering data into the APECS or the ACT Entering values outside of safe operating range can result in serious physical injury and or damage to the equipment or application Woodward 63 APECS 5000 Electronic Engine Speed Governing System Manual SE 4096 Step 4 Step 5 gt Calibrate the selected features by gt Determine how you would like to gt configuring the listed parameters configure the speed set point logic Engine Cranking Default No external analog input Speed Momentary p CRANK DUTY CYCLE 95 Use speed switch to select up to four Switch Switch CRANK 2 RU
85. or attached to the engine throttle lever or mechanical fuel injection pump Desired engine speed may be fixed or selected with one or more switches a potentiometer or some other means A schematic representation of the APECS 5000 system is shown in Figure 1 APECS 2000 3000 4000 and 4500 were designed to drive any of the many Woodward proportional actuators The APECS 5000 controller was designed for use with a Woodward rotary stepper motor actuator that has been environmentally hardened for use on engines This actuator converts pulse commands from the controller to a rotary position such as that required to move the throttle of a small engine Stepper motors provide high torque in a small package with a low current requirement APECS 5000 is ideally suited for use on small one or two cylinder spark ignition gasoline CNG LPG engines The APECS 5000 system provides either isochronous engine speed remains fixed regardless of load or droop engine governing over a wide speed range APECS 5000 is compatible with most common means of sensing engine speed such as magnetic pickups ignition systems and Hall Effect sensors Inputs are user configurable for a wide variety of on and off highway applications Desired engine speed can be preset or based on a pedal input switch inputs or a combination or the two An engine protection switch input and an auxiliary output assist the user in getting the maximum value out of a single electronic
86. password protected to prevent unauthorized calibration changes See Change APECS Password for more information Change APECS Calibration The Change APECS Calibration command allows you to calibrate configure and adjust various parameters associated with the APECS controller APECS 5000 is a programmable engine governor Changing APECS calibration parameters is the means to configure the APECS controller for specific engines applications and environments and for adjusting PID gains The calibration parameters have been organized into categories for your convenience Browse through the categories to view the specific parameter you want to change or adjust Some parameters must be set before the engine can run Other parameters can be adjusted while the engine is running See List of Parameters in Chapter 4 Woodward 27 APECS 5000 Electronic Engine Speed Governing System Manual SE 4096 All adjustments are stored immediately in non volatile memory in the APECS unit The APECS controller will retain the changes even if power is lost or the ACT is disconnected To Change APECS Calibration Parameters 1 Choose Calibrate gt Change APECS Calibration Set the View Filter to select a group of parameters Use F5 F6 to scroll through the list Pp pP 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 th
87. peed either increases at RAMP UP RATE or decreases at RAMP DOWN RATE to the speed selected by the switch SET SPEED 1 or SET SPEED 2 When the other speed is selected with the switch commanded engine speed is ramped to the new set speed rotary switch is used to select among three set speeds The engine is started and transitions from crank mode to run mode The commanded engine speed will increase from SET SPEED MIN to SET SPEED WARMUP at the RAMP UP RATE 3 THREE SPEED Engine speed remains at the warm up speed for WARMUP TIME seconds after which the engine speed either increases at RAMP UP RATE or decreases at RAMP DOWN RATE to the speed selected by the rotary switch SET SPEED 1 to SET SPEED 3 When another speed is selected with the switch the commanded engine speed is ramped to the new set speed Woodward 49 APECS 5000 Electronic Enqine Speed Governing System Manual SE 4096 CONFIGURATION DESCRIPTION MODE A rotary switch with two diodes is used to select among 4 set speeds The engine is started and transitions from crank mode to run mode The commanded engine speed will increase from SET SPEED MIN to SET SPEED WARMUP at the RAMP UP RATE Engine speed remains at the warm up speed for WARMUP TIME seconds after which the engine speed either increases at RAMP UP RATE or decreases at RAMP DOWN RATE to the speed selected by the rotary switch SET SPEED 1 to SET SPEED 4 When another speed is selected with
88. potentiometer e g pedal potentiometer switches or a combination of the two lt operates in either isochronous or droop mode where droop is user selectable up to 15 The controller is software programmable and has no manual adjustments A calibration tool ACT is used for programming configuring and adjusting the APECS 5000 controller o Woodward APECS 5000 Electronic Engine Speed Governing System Manual SE 4096 Calibration Tool ACT The All purpose Calibration Tool ACT is a PC personal computer based software calibration and monitoring tool ACT is designed specifically for use with engines equipped with the APECS 5000 controller The tool can be run on any IBM compatible computer that meets the requirements listed in ACT Installation Once the APECS 5000 controller has been programmed ACT may be disconnected The APECS 5000 unit will continue to operate normally with ACT either connected or disconnected Speed Sensor APECS 5000 monitors engine speed continuously Engine speed may be sensed by monitoring the frequency of spark events in spark ignition engines or through the use of a sensor that detects the passing of teeth on an engine driven gear e g flywheel The universal speed input of the APECS 5000 is compatible with the following types of speed input signal e Magnetic pickup See photo below of mag pickups available from Woodward e Coil type spark ignition Speedcan be sensed from th
89. ronic Engine Speed Governing System Manual SE 4096 Droop Governing When governor droop is non zero governed speed reduces with increasing load Droop may be desirable in certain load sharing applications e g two gensets tied to the same electrical bus When droop is set to zero governed speed will be insensitive to load isochronous Calibration Parameters Needing Configuration DROOP_STEP_MAX Value of step when operating at maximum engine load Used in conjunction with the droop governing feature DROOP_STEP_MIN Value of step when operating at no engine load Used in conjunction with the droop governing feature DROOP PERCENT Desired engine droop Range 0 15 Droop is calculated as follows Droop step DROOP_STEP_MIN DROOP_STEP_MAX DROOP_STEP_MIN Calibration Procedures When operating in droop governing mode the engine speed decreases droops as the load is increased Monitor parameter step at no load and at full load and set DROOP STEP MIN and DROOP_STEP_MAX to these values respectively Set DROOP_PERCENT to desired droop up to 15 Load is inferred by measuring the actuator sense current output of the current driver Set DROOP_PERCENT to zero for isochronous governing 60 Woodward APECS 5000 Electronic Engine Speed Governing System Manual SE 4096 Chapter 5 Troubleshooting AS See Troubleshooting Guidelines Please follow the checklist below to troubleshoot your APECS controller
90. s necessary to maintain the set desired speed Setting KEY_ON_DUTY_TIME seconds to a non zero value will cause the actuator to be driven to the crank duty cycle even if no engine speed signal is present The actuator is energized at key on reset for the set amount of time This may be useful for generator applications where it is desirable to sense engine speed from the generator frequency To keep speed voltage below 75 Vms a step down transformer may be necessary When this feature is used it is especially important to have a redundant overspeed protection device because a broken speed input wire could cause the engine to run at wide open throttle for up to KEY_ON_DUTY_TIME Diagnostics Calibration Parameters This section covers diagnostic calibration parameter configuration Engine Protection Input User selectable input to protect against adverse conditions such as high coolant temperature or low oil pressure In case of oil pressure allows the engine time for oil pressure to rise following startup Calibration Parameters Needing Configuration Woodward 55 APECS 5000 Electronic Enqine Speed Governing System Manual SE 4096 ENGINE PRTCT RUN TIME The time in seconds that the engine must be running before the engine protection logic begins to monitor the engine protection input This permits the APECS 5000 to automatically account for oil pressure switches and similar devices that indicate a fault condition when the engi
91. signal e Overspeed Underspeed Protection e PID Gain Adjustment allows governor response to be adjusted by user e PTO Switch Input allows selection between analog speed setpoint input and switched speed setpoint inputs in mobile applications e Switched Speed Setpoint Inputs allow multiple speed settings using switches This feature can be configured together with the analog input speed pot for a variety of speed select options e Stepper Motor Configuration Permits configuration of stepper range of travel and direction of travel as well as step speed To incorporate any of the above features in your system refer to the Features Table below to determine if additional hardware installation or software configuration is required 6 Woodward APECS 5000 Electronic Enqine Speed Governing System Manual SE 4096 Features Table All features available with the APECS 5000 can be easily installed and configured to work with your application Refer to the table below to determine if additional hardware installation is required Software setup is always required to properly configure the feature Hardware required for the features is customer supplied and is not sold or supplied by Woodward FEATURE RE orbe ira Autocrank Yes Auxiliary Output Yes Droop Governing No Engine Protection Input Yes Engine Start Calibration No Overspeed Underspeed Protection No PID Gains Adjustment No PTO Switch Input Yes Analog Spee
92. t also to configure it properly for different applications Why do we need to calibrate the APECS system APECS 5000 is a software programmable system and has no manual adjustment Calibrating is the only means of configuring and adjusting the controller for your specific application Do need to calibrate ALL the parameters to make my system work No Two parameters PULSES PER UPDATE and PULSES PER REV are factory set to prevent the APECS unit from calculating an engine speed and driving the actuators These two parameters must be calibrated to a non zero value before normal APECS operation can begin Other parameters are preset to values that will work with many engines and applications However it is recommended that you review all settings for your own application 40 Woodward APECS 5000 Electronic Enqine Speed Governing System Manual SE 4096 Is it possible to enter values in APECS in excess of what the application is capable of performing Yes While ACT the calibration tool restricts you from entering values outside of the specified range the range itself is fairly wide and it is possible to enter values in excess of what your application is capable of performing For example it is possible to command engine speeds up to 8192 rom with ACT Your engine may or may not be able to operate at this speed It is also possible to damage the generator or pump attached to your engine by commanding maximum engine speed because whi
93. the connector on the harness The interface harness is inserted between the J1 Grey connector of the controller and the mating connector in the user s wiring harness 20 Woodward APECS 5000 Electronic Engine Speed Governing System Manual SE 4096 COMPUTER INTERFACE MODULE RS 232 CABLE Figure 15 ACT System Set Up Software Set Up ACT software can be automatically installed on your hard drive from the CD ROM supplied with the kit To install the software on your hard drive follow the procedures below NOTE Make sure power to the PC and the APECS unit is off when making connections The engine may or may not be running 1 Turn on your computer and insert the ACT disk into the CD ROM drive The install program should automatically launch If it does not open Windows Explorer go to the CD ROM drive and double click on the install 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 To run the ACT software please refer to Running the ACT Software below e Put the original CD ROM in a safe place in case the files on your hard drive are damaged or lost Woodward 21 APECS 5000 Electronic Engine Speed Governing System Manual SE 4096 Basic ACT Operation R
94. tion of low electrical resistance and mechanical strength Wire insulation should be appropriate for engine applications Excessive length or inadequate gauge can cause increased wire resistance that can limit the current to the actuator and prevent full actuator travel 7 Increased electrical resistance can also result from poor wiring techniques It is important to use good quality terminations and proper crimping technique during wiring Terminations must be impervious to moisture to prevent shorts and corrosion Controller Installation Controller Wiring The controller can be installed in the engine compartment maximum temperature 185 F 85 C Figure 5 APECS 5000 Dimensions 10 Woodward APECS 5000 Electronic Engine Speed Governing System Manual SE 4096 Table 1 Controller Wiring Stepper Motor Output SP1A J1 5 SP1B J1 6 Stepper Phase 1 SP2A J1 8 SP2B J1 7 Stepper Phase 2 Analog Input APP 32 12 Vrer 42 11 SRTN J2 2 TT VBAT 41 9 pur TEN Idle Verification IVS J2 5 Vear J1 9 Power Take off PTO J2 6 Vear J1 9 Rack Position Sensor RPS J2 1 RCV J1 12 TXD J1 1 Re SOE Vago J1 11 GND2 1 2 Speed Signal Input RPM J1 10 RPM J1 3 pe Switched Inputs SW1 J2 7 SW2 J2 8 Switch to Vpar Vaart J1 9 Woodward 41 APECS 5000 Electronic Engine Speed Governing System Manual SE 4096 Controller Pinout
95. troller will automatically learn and store the minimum and range values in its memory Set EXTERNAL ANALOG MODE back to the desired speed mode when finished 50 Woodward APECS 5000 Electronic Enqine Speed Governing System Manual SE 4096 PTO Input This feature allows selection between pedal input and speed switches in mobile applications Calibration Parameters Needing Configuration AUXILIARY OUTPUT MODE This logic value lets the software know how the auxiliary output is configured Set Auxiliary Output Mode 3 to turn on an indicator lamp when in PTO mode EXTERNAL ANALOG MODE This logic value lets the software know how the external analog input is configured See Calibrating APECS Features SWITCH_CONFIGURATION This logic value lets the software know how the speed switch inputs are configured Calibration Procedures Select the appropriate analog input mode and configure the external analog and switched inputs according to your application In the PTO ON mode select the speed with speed switches In PTO OFF mode use the pedal or the pot to adjust the speed As a Safety feature in drive by wire mode only when the engine is initially turned on the mode is assumed to be PTO OFF regardless of the PTO switch setting Users have to cycle the PTO switch OFF and then back ON to enable PTO input CAUTION If a drive by wire mode is being used 003 013 023 103 113 203 213 the
96. unning the ACT Software The ACT software is fairly easy to use Follow the procedures below to run the program Make certain that the APECS i controller is powered up and connected to the computer s COM Copyright 2004 Woodward Inc This software and the accompanying written matenals are copyrighted po ri This software may not be copied in whole o n pait j regardless of the form of media without prior wintten consent of Woodward Inc f i f h b e Woodward Inc makes no warranties express or implied with respect to the software or its quality a n ICO n O r t e Ca ratio n too performance merchantability or fitness for any particular H H purpose The software ts bcensed and delivered as is exists double click on it to start the i Any damages loss of property or other costs resulting ACT softwa re T h e icense screen from the use of this software is the sole responsibility of the indridual or organization using will be displayed when the ACT is launched You must either accept the terms or Cancel which exits the Se application SE If no icon exists click on the Start button highlight Programs find the ACT software and click to start it Default is Woodward then select APECS EPS Calibration Tool Make sure the COM port designation in ACT matches the serial port on the back of your PG Follow the procedure outlined in the Configure Menu to change the COM port
97. us display every time the controller sends the fault_flags status This happens several times a second 2 Click on the Pause button to stop the automatic update of this screen The text on the button will change to Start and clicking it again will re start the automatic updating NOTE If any other screen requests data from the controller while this screen is updating this screen will automatically Pause Control Strategy This command allows you to check the version of the control strategy in use This information may be needed for strategy identification purposes and for future updates Parameter List The Parameter List screen allows the user to adjust which parameters are CalFie Name Bm displayed on the Parameter View mo gt display En View Position To Display the Parameter List core i R eps_deadband 1 Choose Monitor gt Parameter ccna ine List from the main menu GE flagbyte1 flagbyte2 lamp_flash entr 2 The F5 F6 keys will p conversion fecr yy Len see backup advance through the FS PREVIOUS F6 NEXT F9 ADD REMOVE ON VIEW ESC CANCEL EDIT CLOSE gt gt gt list Press F9 or click on On Woodward 35 APECS 5000 Electronic Engine Speed Governing System Manual SE 4096 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
98. ve and the engine could be shut down in the unlikely event that noise on the speed signal input caused a high miscalculation of engine speed A minimum value of 250 msec is recommended The user should realistically determine an overspeed tolerance time When an overspeed condition is detected the duty cycle goes immediately to zero This should stop the engine or at least drive it to minimum speed A fault code is generated and the LED flashes The fault will continue to flash so that the user is made aware of why the engine stopped The engine may be restarted without resetting the unit The fault will then recover and stop flashing By default overspeed is disabled This is because a properly tuned PID governor will decrease the duty cycle to the actuator any time engine speed is above the set point So ordinarily overspeed is not necessary It is disabled by setting OVERSPEED_RPM to zero However if a user feels the need for a more aggressive response to an overspeed condition the overspeed diagnostic feature may be used Woodward 57 APECS 5000 Electronic Enqine Speed Governing System Manual SE 4096 Actuator Output Calibration Parameters This section covers actuator output calibration parameters configuration Stepper Motor Configuration STEP MAX STEP Maximum travel of stepper motor actuator in steps of 1 8 This if the actuator requires a travel of 90 set STEP MAX STEP 50 Default value 40 steps 72 STEP_MO
99. ve minimal friction binding and backlash The bracket and linkage should be designed to use as much of the actuator travel as possible This improves angular resolution and reduces torque on the actuator 4 Fasten actuator to bracket and bracket to engine Attach necessary linkage between actuator shaft and fuel control lever Move linkage end to end to confirm correct travel 5 Connect actuator wires use twisted pair with more than 1 twist per inch Connect terminals SP1A and SP1B to stepper phase 1 terminals A and C on the stepper motor enclosure Connect terminals SP2A and SP2B to stepper phase 2 terminals B and D on the stepper motor enclosure Stepper motor phases APECS 8008 can also be identified using an ohmmeter Wiring a phase backwards will reverse the direction of rotation but that can be corrected during calibration The mating connector for the stepper motor is Delphi P N 12162188 B which requires four ll eal terminals Delphi P N 12124075 SP1A J1 5 FIGURE 8 Stepper Motor Wiring 6 Actuator travel and direction should be adjusted to assure both maximum start fuel or rated load and minimum shutdown or idle positions 14 Woodward APECS 5000 Electronic Engine Speed Governing System Manual SE 4096 NOTE It is beyond the scope of this manual to discuss detailed actuator selection and installation procedures for all possible applications Please contact the factory for specific information concerning
100. will launch and start the parameter plot view PROPORTIONAL GAIN Sam engine rpm rpm 23600 The application will read the previously Congue MTEGRALGAN ES ndesedlpn mm saved configuration and request the _SavetoFie DERIVATIVE GAIN bm controller to start sending the parameter values The controller sends the data to the PC at a rate that varies with the number of parameters being monitored The application uses the Windows timer functionality to update the screen at the specified rate Note that if the PC is very busy the timer accuracy will vary therefore the screen and generated data files should be considered as reference only Woodward 33 APECS 5000 Electronic Engine Speed Governing System Manual SE 4096 The X axis time scale 25 seconds in the example screen may be shorter than configured due to the resolution of the monitor This value will be adjusted when the graph is resized This also applies to the print functionality for this screen All of the data will be recorded in a revolving buffer for use by the Save to File feature see below The axis scales parameter names update resolution and time scale on the Parameter Plot may be changed as described in the Plot Setup screen PID Gain Adjustments from Plot Display Screen After initial calibration most engines require only a minor adjustment to PID gains to fine tune the system to its optimum level ACT provides a convenient means of adjustin

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APECS® 5000 Electronic Engine Speed Governing System