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Dyn-Loc V User Manual

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1. Hard Over torque 0 Dyno Controller Action Dyno OFF 1 IGNORE overrides other settings Loss of Speed Feedback 0 Dyno Controller Action ESTOP 1 IGNORE overrides other settings Loss of Master Enable 0 Dyno Controller Action Dyno OFF 1 IGNORE overrides other settings External Input 1 0 Dyno Controller Action Dyno OFF 1 IGNORE overrides other set External Input 2 tings 0 Dyno Controller Action ES 1 IGNORE overrides other set Computer Watchdog OP tings 0 Dyno Controller Action ES 1 IGNORE overrides other set Loss of PAU OK OP tings 0 Dyno Controller Action Dyno OFF 1 IGNORE overrides other settings Setup Parameter Hierarchy Operator Interface or COMPUT No El R default Dyn Loc V User Manual Te r Set 0 0 P 11 2D 4 FF Dyn Loc V User Manual me Dyno Power Limit 0 Dyno Controller Action 1 IGNORE t Parameter 0 Description T Loss of PAU ON 0 Dyno Controller Action 1 IGNORE Dyno OFF overrides other settings Loss of Coolant ILK 0 Dyno Controller Action 1 IGNORE Dyno OFF overrides other settings Exceeded Dyno OFF overrides other settings Direction 0 Dyno Controller Action 1 IGNORE ESTOP overrides other settings Sets
2. The dyno controller will remain enabled until one of the following conditions occur The speed reading drops below 10 RPM The operator issues a reset While in an ESTOP state the dyno controller will apply full braking torque i e the dyno error signal will be set to 10 vdc Note A special situation exists if the speed reading is already lt 10 RPM at the onset of the ESTOP In this case the dyno controller assumes the low speed reading may be caused by a broken or disconnected speed sensor and will enable itself for a fixed 10 second period just to be safe An operator can still cancel the ESTOP state by pressing the RESET button on the front panel Dyn Loc V User Manual General Controller Concepts 4 5 Chapter 4 Dynamometer Control 1 7 1 8 4 6 BSTOP Action BSTOP brake stop is similar to an ESTOP except a selectable braking torque is applied during the braking sequence Instead of setting the dyno error signal to 10 vdc as is done during an ESTOP a value between 0 and 10 vdc is output The exact output voltage is determined by the BSTOP Braking Force setup parameter see section 2 0 Setting the BSTOP Braking Force to 100 will resultin the maximum braking torque applied during a braking sequence however this parameter is typically set to a smaller value in order to bring the test system to a gradual stop Note ABSTOPrequest only applies to the dyno controller If an optional throttle controlle
3. Wiring The wiring discussion in the sections that follow refer to the DIGITAL CONTROL connector in Chapter 13 section 4 4 1 General Wiring Regardless of which Interface configuration has been selected several common wiring requirements exist Input Common pins 5 6 18 This is the common input connection to all of the digital input signals At least one pin must be connected to the Common i e output ground of the external source that is driving the Input pins Output Common pins 13 25 Provides a common connection to all of the dry contact output relays The outputs can function as sinking outputs by connecting one of the Output Common pins to the input ground of the external inputs conversely the outputs can function as 24 VDC sourcing outputs by connecting one of the Output Common pins to a 24 VDC supply Note that the Output Commons are fused at 1 A by F1 section 4 0 Loopback IN pin 19 and Loopback OUT pin 7 These connections are optional Internally pin 19 is connected i e looped back to pin 7 allowing the external controller to detect a cable off condition The external host can wire these pins to a digital input or they can be wired into any general safety input e g an ESTOP chain Computer Control Wiring In addition to the general wiring requirements listed in section 3 3 1 the following wiring must be completed Inputs 1 thru8 lt lt Digital Outputs of External Interface
4. 46 Actuator ILK not Requests to enable a throttle controller are denied when the ILK present input is not wired to common The ILK input is an input pin on the THROTTLE CONTROL connector The ILK input is typically passed on to the Throttle PAU then on to the actuator assembly The ILK to common connection is made in the actuator This error is most likely caused by a disconnected or broken actuator cable 47 Mode conflict Occurs in systems with an optional throttle controller when the exists operator attempts to enable a controller while another controller is already enabled and in the same control mode e g speed or torque Change the mode of the disabled controller then try again 48 Cannot start in Occurs in systems with an optional throttle controller when an torque mode operator attempts to enable a controller that is currently in torque mode and no active speed controller exists Change the mode of the controller to a safe mode e g to speed or position and try again An alternate solution is to first enable the other controller in speed mode then enable the selected controller in torque mode 49 No active speed Occurs in systems with an optional throttle controller in response control exists to mode change requests that would result in an enabled controller running in torque mode with no enabled controller controlling speed 50 Soft shutdown Requests to enable a controller are denied when a soft shutdown exists condition
5. Anti Alias Filter and A D Converter Frequency Measurement Logic The following components are unique to a throttle controller configuration PID Position Controller The throttle controller implements a second PID control loop that controls the position of a throttle actuator When running in position mode position setpoints are sent directly to this inner loop When running in non position modes e g speed or torque position setpoints continuously arrive from the outer control loop The P I and D coefficients and the feedback filter parameter are set at the factory They are available as setup parameters and can be modified as needed however the factory default values should suffice in all installations Position Control Variable The position control variable object is responsible for input scaling and calibration of the position feedback signal Several forms of position feedback can be selected digital encoder feedback analog actuator position feedback or throttle position sensor feedback Most systems use a Dyne Systems actuator which uses digital encoder feedback Actuator Encoder Feedback The Dyne Systems actuator provides digital encoder feedback The encoder counts provide relative actuator position movement information only thus it is imperative the actuator always be returned to the 096 position when power is removed from the system If not the actuator 0 position must be re established when power to the Dyn
6. DyneSystems Inc VIGNE SE amp Dynamatic Dynamometers Ress Dyn Loc V Dynamometer Controller O Dyn Loc V USER MANUAL www dynesystems com DPD 010 02 No part of this manual may be reproduced or transmitted in any form or by any means including photocopying recording or using information storage and retrieval systems for any purpose other than the purchaser s own use without the express written permission of Dyne Systems Inc 92015 by Dyne Systems Inc All Rights Reserved Any other product names and services identified in this manual are trademarks or registered trademarks of their respective owners No such uses or the use of any trade name is intended to convey endorsement or other affiliation with Dyne Systems Inc Contact Information Shipping Address W209 N17391 Industrial Drive Jackson WI 53037 Mailing Address W209 N17391 Industrial Drive Jackson WI 53037 Toll Free Phone 800 657 0726 Fax 262 677 9308 Web www dynesystems com E Mail sales 2 dynesystems com Document Revision History Version Date Comment 01 01 APR 2012 Initial Release 02 01 NOV 2015 First major update Product Software Revisions This document is up to date with respect to the following versions of product software Product Version Dyn Loc V Main Computer 3 009 Front Panel Interface 1 002 Table of Con
7. Note When configured for by wire external speed control the throttle controller is permanently locked in speed control mode No other control modes are allowed The following parameter settings are required to properly configure a throttle controller for by wire speed control The Control Output Type parameter must be set to Speed Cmd gt Motor One throttle controller programmable analog output see section 8 1 must be configured with a Source set to Command Voltage speed This analog output is wired to the external motor speed controller The Command Voltage 0 and Command Voltage 100 parameters see section 5 8 must be set based on the input specifications of the external motor speed controller e Compute and set the value of the feed forward control parameter in the speed PID parameter set as described in Chapter 6 section 5 1 Optional Internal Speed Control If the external motor drive unit and associated speed controller provides poor speed regulation or provides no closed loop speed control at all the Dyn Loc V can provide additional speed control as explained in Chapter 6 section 5 2 Control Output Types Dyn Loc V User Manual 5 7 Chapter 11 Throttle Control Speed Cmd gt Motor 4 Quadrant This control type is identical to the previous control type 1 e Speed Cmd gt Motor except that operation in all 4 quadrants is allowed The foll
8. Programmable Analog Outputs The throttle controller has three programmable analog output signals These outputs exist on the ANALOG I O connector Programmable Analog Outputs are described in Chapter 4 section 4 1 Analog Inputs The throttle controller has no spare analog inputs however the Throttle Position Sensor input and the Analog Actuator Position input can be used for other functions if they are not being used for their originally designed purpose These inputs can be used as analog inputs for other features as described in Chapter 4 section 4 3 Connector Summary All throttle controller back panel connectors are listed below Detailed pin out information for all connectors is listed in Chapter 13 section 4 2 TPS Feedback from a Throttle Position Sensor is wired into this connector Wiring setup and calibration of TPS feedback signals is presented in section 6 2 3 ANALOG I O Programmable analog outputs exist on this connector See Chapter 4 section 4 1 to setup these outputs THROTTLE CONTROL The throttle control connector is always wired directly to the Dyne Systems Throttle Power Amplifier Unit Jumpers The following jumpers exist on a throttle controller board 1 e DS604 board They are typically jumpered as needed by Dyne Systems technicians Jumper Function Jumper Position JP1 Controller Board ID Position 2 ALWAYS JP2 Shunt Calibration Selection Chapter 7 section 2 5 1 JP3 4 5 Sin
9. automobile odometer digit rollovers will affect adjacent digits Also a decimal point will be added to the appropriate digit in order to match the configured resolution of the controlled variable After the desired value has been loaded into the switches the red button immediately to the left of each set of lever wheels must be touched to issue the set point to the controller Complete instructions regarding lever wheel loading and issuing setpoints is described in section 4 3 Indicators The lower portion of the main screen contains four indicators Master Computer Indicates the Master Computer mode of the controller This indicator is green and displays Master when the controller is in Master mode otherwise it is white and displays Computer See Chapter 4 section 1 1 for more information on Master and Computer modes On Off Indicates the Enabled Disabled state of the controller This indicator is green and displays On when the controller is enabled otherwise itis white and displays Off ESTOP Indicates the ESTOP state of the Dyn Loc V This indicator is bright red when the Dyn Loc V is in an ESTOP state otherwise it is white FAULT Indicates the FAULT status of the controller This indicator is red when a controller fault exists otherwise it is white Faults are described in greater detail in Chapter 5 This indictor is also a button When touched a fault list dialog pops up over the m
10. 1 Description THROTTLE Controller 2 Active Parameter Set Number 0 3 Calculated Power Units HP 4 Calculated Power Display Resolution 1 10 Control Output Type Actuator Motor gt Engine 11 Soft Over speed Detection Off 12 Soft Over speed Limit 0 0 13 Mode Conflict Default Mode Torque Position 0 Display Resolution 0 1 1 Display Units 2 Display Filter None 10 Feedback Source Digital Encoder 11 Actuator Direction Clockwise 12 Input Voltage 100 10 0 volts 13 Input Voltage 0 0 0 volts 14 Reference Source Operator Interface or COMPUT Faults dmm Loss of PAU OK 0 Dyno Controller Action Dyno OFF 1 IGNORE overrides other settings No ho Loss of Actuator Encoder ILK 0 Dyno Controller Action ESTOP q Stalled 0 Dyno Controller Action ESTOP Throttle PAU Power Fail 0 Dyno Controller Action ESTOP t Parameter Sets Set 0 0 Description undefined I Speed Parameters Dyn Loc V User Manual Setup Parameter Hierarchy ER 13 9 Chapter 13 Reference 13 10 P I D 0 0 0 0 0 0 E UN HO FE 0 0 Torque Parameters 0P 0 0 11 0 0 2D 0 0 4 FF 0 0 Set 1 Jesss Speed Parameters P 0 0 0 0 0 0 BwWNHE O OH FF 0 0 TENES Torque Parameters pee
11. 3 Dyno Control O General Purpose I O System a Throttle Controller 4 Dynamometer m t3 Calibration Weights Save Modify Done Messages Status ACTIVATED Description DYNO Controller Active Parameter Set Number 0 Calculated Power Units HP 4 Calculated Power Display Resolution 1 10 Hard Over speed Limit 0 0 RPM 11 Hard Over torque Limit 0 0 LB FT 12 At Speed Threshold 1 0 0 RPM 13 At Speed Threshold 2 0 0 RPM 14 At Speed Deadband 1 0 0 RPM 18 At Speed Deadband 2 0 0 RPM i 18 Loss of Speed Feedback Start Delay 1 0 seconds 1 2 3 2 Setup Tree Basics All Dyn Loc V configuration parameters are organized using a standard Windows style configuration tree top portion of previous figure Each folder may contain configuration parameters and or other sub folders If a folder does contain configuration parameters these parameters will appear on the Parameter List bottom portion of previous figure when the folder is selected Some folders only contain other sub folders i e they contain no parameters Dyn Loc V Setup Parameters Dyn Loc V User Manual 1 3 1 4 1 4 1 1 4 2 te Chapter3 Setup Basics Parameter List Basics The parameters in a selected folder if any are listed on the lower portion of the Setup page The parameter list has three columns ID Description Value Setup Tree and Parameter List Navigation If a stylus is available the setup tree and t
12. 6 6 Tuning Page Display Dyn Loc V User Manual Chapter6 Tuning 4 0 Tuning Security Tuning is a secured feature The Dyn Loc V administrator can optionally disable access to the tuning page for other operators Tuning security is discussed in Chapter 9 5 0 Feed Forward Control The basic PID control structure shown at the beginning of this chapter provides a control solution for most control applications however some control problems e g by wire speed control require an additional control element feed forward control The control structure shown below is a basic PID control structure but contains an additional feed forward element i e Kff gt Kg Kp Reference PEN OS e gt Kas Feedback Filter rad Feedback a Notice the feed forward control element Kff provides a direct connection of the ramped reference to the composite error output By wire control applications e g by wire speed control requires the Kff parameter to be properly set the remaining parameters i e Kp Ki and Kd are all set to zero Note Feed forward control is useful in a limited number of applications Please contact DyneSystems to discuss your application prior to setting the feed forward parameter 1 e Kff Dyn Loc V User Manual Feed Forward Control 6 7 Chapter6 Tuning 5 1 5 2 6 8 K Computation The feed forward parameter must be set to match the internal s
13. Dyn Loc V User Manual Reference Sources 7 17 Chapter 7 Transducers 3 3 3 3 1 7 18 When an analog reference source is active the displayed reading will alter its appearance as shown below Instead of enclosing the commanded setpoint in parentheses the analog setpoint value is enclosed in brackets Setpoint enclosed in brackets Analog Reference Scaling When an analog reference source is selected the respective voltage input must be properly scaled in order to correctly command the desired setpoint reference values The correct scaling depends on the type of setpoint e g speed torque etc being commanded Each is described in the sections that follow Note If the required voltage inputs cannot be generated by the external device that produces the setpoint command voltages addition scaling is available as described in Chapter 4 section 4 3 2 Speed Setpoint When an analog speed reference source is selected a 0 to 10 volt signal at the respective input provides the speed reference during speed mode operation The scaling of this signal is shown below RPM desired 10 0 Voltage ju E RPM Input Dynamic Range The RPM Input Dynamic Range configuration parameter is explained in Chapter 7 section 1 1 For example if this parameter is set to 5 000 RPM a 2 000 RPM analog speed setpoint requires an input voltage of 4 0 volts i e 2000 5000 x 10 volts Note Ifthe device or interface that g
14. Setup Information The existing calibration values are displayed here If digital encoder feedback is used the Zero value will always be 0 counts and the Span will be approximately 50 000 counts If analog position feedback is used the Zero value will display the feedback voltage at the 0 position and the Span value will display the voltage difference between the 100 and 0 positions Setup Mode Three setup modes are available Local mode allows the actuator position be calibrated from this calibration page Remote Station allows the actuator position to be calibrated from a Dyne Systems Remote Station box if any that is usually located in the test cell in close proximity to the actuator itself Manual mode allows the actuator position to be calibrated by manually moving the actuator arm 1 e not using the UP and DOWN buttons Each setup mode is discussed in section 7 3 Which Limit Selects the limit to be calibrated The Lower limit is usually set first If so the calibration procedure assumes the upper limit will be set next and automatically advances to upper limit setup mode after the lower limit has been set To set only the upper limit touch the Upper limit button and proceed to calibrate the 100 position 11 12 Actuator Dyn Loc V User Manual 7 3 7 3 1 Chapter 11 Throttle Control Move Rate Selects the rate of actuator movement during Local and Remote St
15. 0 P 0 0 11 0 0 2D 0 0 3 Feedback Filter None 4 FF 0 0 t Set 6 0 Description undefined doc ed Parameters 0 0 0 0 0 0 Feedback Filter None FF 0 0 BRWwWNRO un OH Us D rr Torque Parameters 0P 0 0 11 0 0 2D 0 0 3 Feedback Filter None 4 FF 0 0 Set 7 0 Description undefined psss ed Parameters 0 0 0 0 0 0 Feedback Filter None FF 0 0 ACNPO un OH U s 0 dices Torque Parameters 0P 0 0 11 0 0 2D 0 0 3 Feedback Filter None 4 FF 0 0 Set 8 0 Description undefined ed Parameters 0 0 0 0 0 0 Feedback Filter None FF 0 0 BRWNRO T un DH US D TE Torque Parameters 0P 0 0 11 0 0 2D 0 0 Dyn Loc V User Manual Setup Parameter Hierarchy 13 5 Chapter 13 Reference 13 6 3 Feedback Filter None 4 FF 0 0 L Set 9 0 Description undefined t Speed Parameters 0P 0 0 11 0 0 2D 0 0 3 Feedback Filter None 4 FF 0 0 t Torque Parameters 0P 0 0 11 0 0 2D 0 0 3 Feedback Filter None 4 FF 0 0 H Dyno Control I O Output 1 0 Source None 1 Invert Polarity No posse Output 2 0 Source None 1 Invert Polarity No Output 3 0 Source None 1 Invert Polarity No de Output 4 0 Source None 1 Invert Polarity No pum mm Output 1 0 Source No
16. 5 3 5 4 5 5 5 6 Input Power The Dyn Loc V requires 24 VDC An appropriate power supply is provided with the unit at the time of purchase Analog Inputs Each controller has four analog 10 volt inputs All have dedicated functions or are reserved for future applications Analog Outputs Each controller dyno or throttle has four analog 10 volt outputs One output provides the controller error signal The other three are available on the ANALOG I O connector of each controller the function of these three analog outputs is programmable see Chapter 4 section 4 1 PLC Style Digital Outputs All digital outputs on all connectors are 24 vdc sourcing PLC style outputs Each individual output can source up to 1A The total available current for all PLC outputs on the DYNO CONTROL connector is limited by the value of F1 see Chapter 4 section 4 6 The total available current for all PLC outputs on the THROTTLE CONTROL connector is limited by the value of F1 see Chapter 11 section 8 5 The total available current for all PLC outputs on the GENERAL PURPOSE I O Connector is limited by the value of F1 see Chapter 8 section 11 0 PLC Style Digital Inputs All digital inputs on all connectors are sinking PLC style inputs A logic 1 input requires Vin gt 12 volts conversely a logic 0 input requires Vin 5 volts Transducer Excitation Transducer Connector Voltage VDC Note
17. An example of the Dyn Loc V diagnostic page is shown below This page provides a very basic operating interface to a controller It is intended for troubleshooting purposes only thus not all functionality compared to Dyn Loc V front panel is available DL5 r Control Power 0 HP mM Enable Tune lv Speed d 0 RPM 0 E W Disable Ramp II 0 0 LB FT Bis sP Send Iv Locked V Ramp Complete Messages Clear Show Faults Connecting to DL5 Faults Connected o Y ESTOPPED Reset BSTOPPED Controller Fault 2 2 Calibration Page This page presents a Calibration Choice page similar to that shown in Chapter 2 section 3 2 3 After selecting the variable to calibrate an appropriate calibration page is displayed Each calibration page is identical to those provided by the Dyn Loc V front panel The torque calibration page is shown in Chapter 7 The position calibration page is shown in Chapter 11 10 2 Device Setup Pages Dyn Loc V User Manual Chapter 10 Cell Assistant 2 3 Setup Page This page provides local setup parameters as well as access to the Dyn Loc V setup parameters The Setup page is shown below Setup Dyn Loc V Setup Sample Frequency 120 Hz Modify Text Dump SAVE To File LOAD From File pel EEE ES The Sampling Frequency should be set as needed Note The Sampling Frequency setting is permanently saved by pressi
18. Note Many Dyn Loc V setup parameters affect the run time operation of the Dyn Loc V thus access to the Dyn Loc V setup pages will be denied when the controller is enabled Note Dyn Loc V setup parameters are secured thus a password may be required to access the Dyn Loc V setup page Security 1s discussed in Chapter 9 2 8 Membrane Keypad Buttons Dyn Loc V User Manual Chapter 2 Operator Interface Front Panel Setup Parameters The Front Panel Setup page is shown below Information regarding each of the setup parameters can be found in the following sections The Screen Saver property commands the front panel LCD display to reduce its display intensity if the configured amount of time expires with no front panel activity Note the screen saver will never activate if any controllers are enabled even if time expires with no front panel activity The Service button launches the SERVICE page as described below This page provides access to tools that are mainly used at the factory Note Front Panel setup parameters have no effect on the run time operation of the Dyn Loc V thus they can be changed at any time Dyn Loc V User Manual Membrane Keypad Buttons 2 9 Chapter 2 Operator Interface SERVICE Page The service page is shown below The Touch Screen Calibrate button launches a tool to recalibrate the touch screen A stylus or similar device is required Note that the touch screen is calibrated at the facto
19. Speed Parameters P 0 0 0 0 0 0 Feedback Filter FF 0 0 EB wmNHO OH dla Torque Parameters Speed Parameters P 0 0 0 0 0 0 Feedback Filter FF 0 0 BB wNHO OH Setup Parameter Hierarchy Feedback Filter None 3 Feedback Filter None 0 Description lt undefined gt Feedback Filter None 0P 0 0 1I 0 0 2D 0 0 3 Feedback Filter None 4 FF 0 0 Set 2 0 Description undefined 0P 0 0 11 0 0 2D 0 0 3 Feedback Filter None 4 FF 0 0 t Set 3 0 Description undefined Dyn Loc V User Manual fe 0 0 Dyn Loc V User Manual Torque Parameters 0P 0 0 11 O30 2D 0 0 3 Feedback Filter None 4 FF 0 0 t Set 4 0 Description undefined Speed Parameters P 0 0 0 0 0 0 Feedback Filter None FF 0 0 BwWNHR OO OH Torque Parameters 0P 0 0 11 0 0 2D 0 0 3 Feedback Filter None 4 FF 0 0 Set 5 Description lt undefined gt Speed Parameters 0P 0 0 11 0 0 2D 0 0 3 Feedback Filter None 4 FF 0 0 Torque Parameters 0P 0 0 11 0 0 2D 0 0 3 Feedback Filter None 4 FF 0 0 Set 6 Description lt undefined gt Speed Parameters P 0 0 0 0 0 0 Feedback Filter None FF 0 0 EB wnmNHO OH Torque Parameters 0 Nro DU HH Il oo Co 0 0 Chapter 13 Setup Parameter Hi
20. The LOWER LIMIT annunciator will turn bright red to remind the operator that the 0 percent position is being established 3 Touchand hold the UP and DOWN buttons to move the throttle to the desired 0 percent position The move rate can be adjusted as explained in section 7 2 Note If touching the UP button moves the actuator in the reverse direction i e towards 0 percent instead of 100 percent the Actuator Direction parameter section 6 1 must be changed Note Touching and holding the DOWN button will move the actuator towards the desired 0 percent position but only until the actuator reaches the existing 0 percent position At this point the actuator stops and the DOWN button must be repeatedly touched to get the actuator to move past the existing lower limit 4 When the throttle is at the desired O percent position touch the ENTER button The position reading is reset to 0 percent the LOWER LIMIT annunciator turns off and the ACCEPT LIMIT annunciator will turn bright red 5 Touch the ENTER button again to accept the new lower limit setting The ACCEPT LIMIT annunciator turns off and the calibration procedure automatically proceeds to set the 100 percent position The UPPER LIMIT annunciator turns bright red 6 Touchand hold the UP and DOWN buttons to move the throttle to the desired 100 percent position The move rate can be adjusted as explained in section 7 2 Note Touching and holding the UP button will move the a
21. Wire all eight 24 VDC digital outputs on the external controlling interface to Inputs 1 thru 8 on the DIGITAL CONTROL connector The functions of each input are listed in section 3 2 1 If the RESET input is not needed wire this input to one of the Input Common pins i e 5 6 18 If the ESTOP input is not needed it should be wired to 24 VDC Operation of all inputs is described in section 4 1 Outputs 1 thru 8 gt gt Digital Inputs of External Interface Wire Outputs 1 thru 8 on the DIGITAL CONTROL connector to the digital inputs on the external controlling interface The functions of each output are listed in section 3 2 1 Unneeded outputs can Dyn Loc V User Manual Selecting an Interface Configuration 12 5 Chapter 12 Digital Control Card 3 3 3 12 6 be left unconnected Whether these outputs source or sink current is determined by how the Output Common pins are connected as explained in section 3 3 1 Operation of all outputs is described in section 4 1 Push Button Control Wiring In addition to the general wiring requirements listed in section 3 3 1 the following wiring must be completed Inputs 1 thru8 lt lt Momentary Push Buttons Wire eight appropriately labeled momentary push buttons to Inputs 1 thru 8 on the DIGITAL CONTROL connector The functions of each input are listed in section 3 2 2 The remaining terminals on all switches should be wired to a 24 VDC supply with the supply common conn
22. ramp rate is denoted with an up arrow next to the value and is listed at the top of the button similarly the down ramp rate is denoted with a down arrow next to the value and is listed at the bottom of the button Ramp rate units are the same as the units for the respective reading on a per second basis For example the ramp rates shown on the main controller screen figure section 2 0 are 200 RPM second because speed is the active mode with displayed units in RPM When the Ramp Rate button is touched a Ramp Rate dialog pops up over the main screen Entering ramp rate values from this dialog is discussed in section 4 4 Note The displayed up and down ramp rate values will change as the active controller mode is changed because the Dyn Loc V saves unique ramp rate values for each controller mode Note The Ramp Rate button is disabled when the controller is in Computer mode since Computer mode ramp rates are active The currently active Computer mode ramp rate values will be displayed however they can only be modified by the connected host computer See Chapter 4 section 1 1 for more information on Master and Computer modes Main Controller Screen Dyn Loc V User Manual Chapter 2 Operator Interface 3 0 Membrane Keypad Buttons Membrane keypad buttons are organized into three groups Controller Operation Setup Numeric Keypad All membrane keys are edge triggered i e the button action occurs when th
23. 10 digits 116 0 02 lt Speed When configuring a speed input see Chapter 7 section 1 0 the Scaling lt 50 0 Speed Scaling parameter must be in the range of 50 1 to 1 50 Speed scaling is described in Chapter 7 section 1 5 117 Max allowable The Dyn Loc V does not support speed transducers with a PPR is 4096 resolution greater than 4096 pulses per revolution Contact DyneSystems if the resolution of your speed transducer exceeds this value 118 0 25 Min Reset The minimum width ofthe internal RESET state is configurable Duration lt 5 0sec and must be within the specified limits 119 Invalid time date This error should never occur If so it indicates a problem with value the onboard real time clock hardware in the controller 120 Weights 1 Lb Multi point torque calibration requires that all weights be at least or Kg are not 1 Lb or 1 kg allowed 121 Serial Number During multi point torque calibration the serial number of any must be 9 digits or entered weight must be 9 digits or less less 122 129 UNDEFINED 13 22 Error Codes Dyn Loc V User Manual Chapter 13 Reference Calibration Errors 130 149 These errors are displayed when the Dyn Loc V is in calibration mode and invalid parameter values are entered Error Code Text Description 130 Opposite signs When calibrating Torque the polarity ofthe entered span value is not allowed opposite the polarity of the current reading This is not al
24. 4 in all standard Dyn Loc V boxes The top two slots Slot 1 and Slot 2 are reserved for the installation of dynamometer and throttle controller cards The remaining wiring and configuration is performed at the customer site as described in the remainder of this chapter Selecting an Interface Configuration The DIGITAL CONTROL connector is a 25 pin male DSUB connector as shown in Chapter 13 section 4 4 1 This connector provides 8 digital inputs used to issue controller commands and 8 digital outputs used to output controller status The exact function of each input and output bit depends on the selected interface type for this digital control interface Two interface configurations are supported Select the configuration that best supports your control requirements They are described below in section 3 2 Setup Parameters The following parameters determine the functionality of the Digital Control interface Path WDyn Loc V Digital Control Card ID Parameter Values Description O Interface Type Disabled Selects the configuration 1 e the function Computer Control of all Inputs and Outputs of the DIGITAL Push Button Control CONTROL connector All available Interface Configuration Types are described in section 3 2 The Digital Control interface can be completely disabled by setting the Interface Type parameter to Disabled When disabled all digital outputs are set to zero 1 e relays are open and al
25. Change controller selections as needed to send commands to various controllers after a command is issued maintain the controller selection to verify the resulting controller status Please do NOT create status scanning loops for example that continuously change the controller select bits This will cause the outputs relays to continuously switch back and forth from one controller status to another This can easily reduce the useful life of the relay outputs by several orders of magnitude 12 10 Operation Dyn Loc V User Manual 4 2 4 2 1 4 2 2 4 2 3 Chapter 12 Digital Control Card Push Button Control Operation The sections that follow describe what an operator must do in order to digitally control a single dynamometer and or throttle controller Enabling the Interface In order to prevent spurious controller enabling and or controller mode changes several safety features have been incorporated into the Digital Control feature First of all after the Dyn Loc V is powered up the Digital Control feature is completely disabled until the Dyn Loc V is reset This prevents any spurious activity on the inputs from being acknowledged until the reset occurs The reset can be issued from one of several sources the RESET input on the GENERAL PURPOSE I O connector the RESET button on the Dyn Loc V front panel etc Secondly the reset itself will not be acknowledged for a period of 2 seconds after the Dyn Loc V has powered up
26. Dyne Systems technical support specialists Document Conventions Important information that would be overlooked if buried in larger paragraphs of the manual are broken out as Notes Notes are usually itemized at the end of various sections A sample note is displayed below Note This is an example of a note Notices Dyn Loc V User Manual Chapter1 Introduction Dyn Loc V User Manual Notices 1 5 Chapter 2 Operator Interface The Dyn Loc V front panel is the main user interface for the entire controller The front panel provides access to all Dyn Loc V controller functionality including data acquisition control setup tuning calibration etc 1 0 Front Panel Components The front panel of the Dyn Loc V is shown below The three major components are the LCD display and touch screen the membrane keypad buttons and the Emergency Stop ESTOP button Each component is discussed in the sections that follow LCD Display with Touch Screen Membrane Keypad Buttons Chapter 2 Operator Interface 1 1 1 2 1 3 2 2 LCD Display with Touch Screen The most prominent front panel component is the 7 active matrix LCD display Readings controller status and other information are displayed here The layout of the main controller screen is described in section 2 0 The display also contains a resistive touch screen Touch screen buttons are large enough to be touched by a finger On some screens a touch screen stylus
27. General Purpose I O Programmable Digital Outputs Output N ID Parameter Values Description O Source None Selects the signal source for this programmable output source 1 Choices depend on the number and type of installed source 2 controllers they are summarized in the tables that follow BT Default selection None source N Invert polarity Yes No Invert polarity of output if necessary Note If the Source of a programmable output is set to None and Invert Polarity No the output will be permanently de asserted On the other hand if the Source of a programmable output is set to None and Invert Polarity is set to Yes the output will be permanently asserted Signal Sources Source Description At Speed 1 Assert output when speed reading is equal to or greater than the value specified by the At Speed Threshold 1 setup parameter see Chapter 4 section 2 0 A deadband exists below this threshold such that this output will only be de asserted when the speed reading is equal to or less than At Speed Threshold 1 minus At Speed Deadband 1 The At Speed Deadband 1 setup parameter is also described in Chapter 4 section 2 0 Output is always valid including when the controller is disabled At Speed 2 Provides another At Speed output using the At Speed Threshold 2 and At Speed Deadband 2 parameters See previous it
28. Loc V is restored This is typically not an issue since the Dyn Loc V detects all power fail situations and has sufficient stored energy to return the actuator to the 0 position before power is completely lost Analog Actuator Position Feedback The throttle controller can optionally accept an analog input voltage that represents the absolute position of the actuator Dyn Loc V User Manual Theory of Operation 11 21 Chapter 11 Throttle Control TPS Sensor and Feedback The throttle controller can optionally accept an analog input voltage from an external customer supplied Throttle Position Sensor THR PAU and Actuator Dyne Systems provides a high performance actuator and a throttle power amplifier unit Together these devices are capable of actuator slew rates up to 500 per second The THR PAU also contains sufficient energy storage to return the actuator to a safe 0 position in power fail situations 11 22 Theory of Operation Dyn Loc V User Manual Chapter 12 Digital Control Card 1 0 Overview An optional Digital Control card is available for the Dyn Loc V providing digital control of up to two installed controllers by an external source e g a set of hard wired push buttons or digital I O on another host computer This is a purchased option that must be installed at the factory A feature summary is listed below Provides digital control of the Dyn Loc V AND an optional throttle controller Edge triggered com
29. Throttle Control 1 01 Analog Inputs Input N ID Parameter Values Description O Offset Adjustment 0 0 volts This voltage value is added to the incoming input voltage 1 Gain Adjustment 1 0 This value is multiplied by the offset adjusted input voltage 2 Input Filter None Selects a low pass filter to be applied to the offset 50 Hz and gain adjusted input voltage This filter should 30 Hz be used for electrical noise reduction and not as a 20 Hz substitute for incorrect ramp rate settings 15 Hz 10 Hz 7 0 Hz 5 0 Hz 3 0 Hz 2 0 Hz 1 5 Hz 1 0 Hz Connector Summary All dynamometer controller back panel connectors are listed below Detailed pin out information for all connectors is given in Chapter 13 section 4 1 SPEED Speed feedback from an encoder or magnetic pickup is wired into this connector Wiring setup and calibration of speed feedback signals are presented in Chapter 7 section 1 0 TORQUE Torque feedback from a load cell or in line torque sensor is wired into this connector Wiring setup and calibration of torque feedback signals are presented in Chapter 7 section 2 0 ANALOG I O Programmable analog outputs exist on this connector See section 4 1 to setup these outputs Two analog inputs are also available on this connector The functionality these inputs provide is described in section 4 3 DYNO CONTROL This connector is wired directly to the Dyne Systems EC PAU for eddy
30. and 100 positions Calibration is the process of defining the 0 and 100 positions Regardless of which setup i e calibration mode is used the goal of position calibration is to move the actuator to each of these positions and mark them Each setup mode is discussed in the sections that follow Note At the end of position calibration touch the Save button to permanently save the actuator position settings Local Mode Calibration Local calibration is performed entirely from the calibration page on the throttle controller front panel This method is useful if the front panel is located in the test cell near the actuator and or the connected throttle mechanism The actuator positions are adjusted by touching the UP and DOWN buttons yet the operator must be able to simultaneously see the position of the actuator arm and or throttle mechanism If this is not possible a second operator will be needed to press the front panel buttons while the first operator watches the position ofthe throttle If this is not possible the second and probably preferred solution is to use the Manual calibration method described in section 7 3 3 The Local calibration procedure is as follows Dyn Loc V User Manual Actuator 11 13 Chapter 11 Throttle Control 1 Touch the Local button in the Setup Mode group This activates all on screen setup buttons 2 Touchthe Lower button to begin calibration of the 0 percent throttle position
31. button can be used to jog the actuator past the existing setup mode lower limit This is allowed only until the actuator reaches the absolute lower limit of the actuator position encoder This notification message is then displayed It informs the operator that jogging is no longer allowed and that they should switch to Manual setup mode if additional lowering of the lower limit is required 24 At upper limit During Local or Remote Station actuator setup modes the Switch to Manual UP button can be used to jog the actuator past the existing upper setup mode limit This is allowed only until the actuator reaches the absolute upper limit ofthe actuator position encoder This notification message is then displayed It informs the operator that jogging is no longer allowed and that they should switch to Manual setup mode if additional raising of the upper limit is required 25 29 UNDEFINED Controller Run Time Errors 30 99 These errors are usually returned after a button press or operator action that is not permitted at this time Error Code Text Description 30 ESTOP exits Mode change and controller enable requests are denied when the Dyn Loc V is currently in an ESTOP state The ESTOP condition must be cleared before the mode change or enable request will be accepted 31 UNDEFINED 32 Controller fault Requests to enable a controller are denied when a controller fault exists condition exis
32. can be used for more precise manipulation of screen controls however the stylus is not absolutely necessary All screen controls can easily be manipulated using various membrane keys e g ENTER CANCEL and the arrow keys Note In order to avoid ambiguity in describing the operation of some screens the word touch will be used to refer to the activation or pressing of touch screen buttons whereas the word press will be used to refer to the pressing of membrane keypad buttons Membrane Keypad The LCD display is surrounded by groups of membrane keys These keys are activated when they are firmly pressed The membrane keys are divided into three groups Controller Operation keys Setup keys e Data input keys Refer to section 3 0 for additional information on key types Emergency Stop ESTOP Button The ESTOP button is wired directly into the hardware ESTOP circuit of the Dyn Loc V Gently punch the ESTOP button with the palm of your hand to generate a total system ESTOP Twisting the button in the clockwise direction releases the ESTOP button Note Releasing the ESTOP button will NOT clear the ESTOP state ESTOP is a latched state All ESTOP inputs must be de asserted and then the RESET button must be pressed in order to clear the ESTOP state Front Panel Components Dyn Loc V User Manual Chapter 2 Operator Interface 2 0 Main Controller Screen The main controller screen is displayed during normal operation of
33. condition A zero speed reading is allowed for a few seconds when the controller is initially enabled as described in section 2 0 Loss of Master Enable 24 vdc is no longer present at pin 16 of the GENERAL PURPOSE I O connector External PLC logic may have de asserted the Master Enable single due to other externally detected error conditions External Input 1 External circuitry is issuing a fault request for this controller via a programmable digital input see Chapter 8 section 6 0 This fault condition is continuously monitored External Input 2 A second external fault input is provided allowing a different set of fault actions to occur in response to other external conditions See description for External Input 1 above for more information Computer Watchdog The controller is in Computer mode and the Computer Watchdog programmable digital input on the GENERAL PURPOSE I O connector is not asserted i e 24 vdc not present See the description of the Computer Watchdog programmable digital input Chapter 8 section 6 1 for more information Dyn Loc V User Manual Controller Operation 4 19 Chapter 4 Dynamometer Control 4 20 Fault Description Loss of PAU OK 24 vdc is no longer present at pin 19 ofthe DYNO CONTROL connector This error is most likely due to an EC PAU hardware failure External PLC logic can also cause a controller fault by wiring in to the PA
34. current applications Controller Hardware Dyn Loc V User Manual Chapter 4 Dynamometer Control 4 5 Jumpers The following jumpers exist on a dyno controller board i e DS603 board They are typically jumpered as needed by Dyne Systems technicians Jumper Function Jumper Position JP1 Controller Board ID Position 1 ALWAYS JP2 Shunt Calibration Selection See Chapter 7 section 2 5 1 JP3 4 5 Single ended Encoder Setup See Chapter 7 section 1 3 1 4 6 Fuses F1 Install a 1A fast acting fuse BUSSMAN GMA 1A This fuse limits the total current that the PLC outputs on the DYNO CONTROL connector can draw from the 24 vdc supply which is input on pins 11 12 and or 13 of the same connector Dyn Loc V User Manual Controller Hardware 4 17 Chapter 4 Dynamometer Control 5 0 Controller Operation 5 1 5 2 4 18 Enabling the Controller When the dynamometer controller receives an enable request it first reviews an internal list of conditions that must and or must NOT exist in order to enable the controller If all conditions are satisfied the controller is enabled If not an appropriate error message is reported The following conditions must NOT exist when attempting to enable the controller e ESTOP e BSTOP e Controller Fault e Soft Shutdown e Controller is Disabled due to previous fault see Chapter 5 section 2 1 e Reset continuously asserted Pressing the RESET button will attempt
35. is important to file a damage claim with the Carrier promptly If you require assistance in settling the claim contact DS Refer to equipment by purchase order model and serial number Dyn Loc V User Manual Notices 1 3 Chapter 1 Introduction 3 4 3 5 3 6 3 7 3 8 1 4 Training Training programs are an essential part of safe and correct operation Training provides the know how necessary to obtain top performance from your equipment DS recognizes this fact and will conduct training classes on site or at the factory to educate personnel in safe operating and maintenance procedures Electrocution Hazzard This product and associated components are electrically energized Electric shock may cause serious injury or death Always disconnect line voltage before servicing the Dyn Loc V or any associated components Electrostatic Discharge Electrostatic discharge ESD can damage sensitive semiconductors on all circuit boards in the Dyn Loc V and associated components Always wear an ESD grounding device e g a wrist strap when handling internal components Failure to observe ESD grounding precautions may damage sensitive components User Servicing The Dyn Loc V contains absolutely no parts or adjustments that require user access or user servicing The Dyn Loc V should always be returned to the factory for repairs upgrades or other servicing Access to internal components should only be performed under the supervision of
36. is not responsible for determining suitability of Buyer s equipment for a particular purpose Repair or configuration of Buyer supplied equipment will be charged at Dyne Systems normal rate 13 44 Product Warranty Dyn Loc V User Manual
37. of a numeric entry edit box It is also used to duplicate the function of some touch screen buttons e g Cancel Quit etc is some contexts On some dialogs the CANCEL button will do both that is if a data entry box is empty pressing the CANCEL button will dismiss the currently displayed dialog by duplicating the function of atouch screen Done Cancel or Quit button On the other hand if a data entry box is not empty pressing the CANCEL button will first clear the contents of the edit box then pressing the CANCEL button again will dismiss the dialog box as previously described 4 0 Front Panel Operations This section describes front panel operations that are frequently performed by an operator during normal operation of the Dyn Loc V Operators should be thoroughly familiar with each of these procedures 4 1 Controller Mode Changes Controller mode changes are made by touching the appropriate display variable on the touch screen For example to change the controller mode from speed to torque touch the torque reading Note Ifan optional throttle controller is installed some mode changes may be rejected due to a mode conflict Mode conflicts are discussed in Chapter 11 section 9 1 Dyn Loc V User Manual Front Panel Operations 2 13 Chapter 2 Operator Interface 4 2 4 3 4 3 1 2 14 Entering Setpoints When the main display page see figure in section 2 0 is displayed all numeric keypad entries are placed in the
38. onset of controller enable Range 0 0 to 120 0 seconds Dyn Loc V User Manual Controller Setup Parameters 4 9 Chapter 4 Dynamometer Control ID Parameter Values Description 17 Dyno Error Output Yes No The dyno controller outputs 10 vdc to Invert Polarity command full absorbing braking torque and 10 vdc to command full motoring torque This parameter will invert these definitions if required by the external PAU Note The invert polarity parameter should not be used to correct external wiring errors 18 Powerup Mode Speed Determines the initial mode of the controller Torque at power up 19 Timeout Value Coolant 2 0 Range 0 0 to 15 0 seconds See section 5 2 ILK Timeout Coolant ILK fault for more information 20 Timeout Value PAU 2 0 Range 0 0 to 15 0 seconds See section 5 2 ON Timeout PAU ON fault for more information 21 Shaft A B Selection Shaft A always Permanently select shaft A or B or select the Source Shaft B always source of dynamic shaft A B selection Cell Assistant Dual shaft operation is discussed in section Programmable Digital 1 9 Input 22 BSTOP Braking Force 100 of ESTOP Selects the percentage of the ESTOP braking braking force force that will be applied during a BSTOP BSTOP is explained in section 1 7 23 ECPAU ESTOP Current 100 of available Selects the percentage of the available Limit ECPAU braking force ECPAU ESTOP braking for
39. ped ue Ron dpa a A UR ES CARE sas 13 o carris perl ad dandas bue i deus den a eed idee 16 Con cto SUAR ev A DUM becuse eet ese o ds 27 Dynamometer Controller Back Panel sussa 26 uve ERE A ax ds 28 SPEED ec rmm 28 TORQUE iss speed pede Ed DT Lev ED ers Ps d eee dE 29 ANALOG TA use ss Hadid a And gas a SA ipeo rice SEA a 30 DYNO CONTROL vda tras RR SUCI 31 Throttle Controller Back Panel ses spposize paso ss tor s 32 j A A eee E ae ese 32 ANALOG DO ees deg beg Son a been ee A Gla REG ah Ge done A eH PRA ds 33 THROTTLE CONTROL 25 2599 p rre cR RR ERES EE SEES 34 TOC 8 Dyn Loc V User Manual Table of Contents General Purpose I O Back Panel gue sus ioe sed antes yr ee 35 COMPUTER 03300 da REY Ein aan P eR P Ra n 33 VCS LL VCS and OCS 3 ceou isasi ais e fee Espada I E S Pes 35 RA 1 a EET 33 GENERAL PURPOSE UO ss guaranis Salt Rx YEAR AX RR 36 Digital Control Back Panel cssasspzeiacoss falas sigo PEDALS E REOS 37 DIGITAL CONTROL o dia ds DO SA 9 d 37 Electrical Specifications 1 dua escis ps ARA ACE Roe wa 38 Input PONeLs sedi oeahk e QppbaiQasbeeskESESPQLaS4G redada 38 Analog TPUS ouo Se e RETOURS RES Ue SORS eite Ode ed 38 Analog Oufpulls sus ones eked ches Shas rra SAQUE E TAE NS EXE 38 PLE Style Digital OUIpuis 2 25222deu asm sedi ndo s bio ew Eni R ess 38 PLC Style Digital DUIS cu duh reir RE ad RR i pU RES I RR 38 Transducer Excitation essas Sands ead yx X P RR eevee aed 38 Version Tracking ise 4i e S Rad4 esi QIR
40. speed detection is enabled Soft Over speed detection is not performed if the Dyn Loc V dynamometer controller is currently enabled Note A Soft Over speed Occurred state is maintained and reported only to Cell Assistant TestPlans This state is latched and can only be cleared by issuing a controller reset 11 20 Controller Operation Dyn Loc V User Manual Chapter 11 Throttle Control 10 0 Theory of Operation The throttle controller is based on a classical Proportional Integral Derivative architecture Except for basic signal conditioning and electrical isolation the controller is entirely software based The next few sections describe the basic components of the throttle controller The throttle controller architecture is similar to the dyno controller architecture except two control loops are used The outer control loop controls speed or torque It is identical in form and function to the dyno controller control loop but instead of outputting an error signal directly to an external PAU the error signal is converted to a 0 to 100 percent position command and is then fed to an inner position loop The inner position loop is simply another PID control loop that controls the position of a throttle actuator The following throttle controller components are identical to those described in the dynamometer controller description Chapter 4 section 7 0 PID Controller Control Variable D A Converter and Output Filter
41. the Dyn Loc V E 01600 RPM Power HP nn 2 ESTOP FAULT BE DYNO Readings Message Line Indicators The left portion of the screen contains all variable readings for the Dyn Loc V The layout of the lower right portion of the screen contains several indicators a message line the setpoint entry edit box and the ramp rate indicator The upper right portion of the screen contains two sets of virtual lever wheel switches used for setpoint entry 2 1 Readings A typical variable reading is shown below Units Variable Name Reading Locked Status Setpoint Dyn Loc V User Manual Main Controller Screen 2 3 Chapter 2 Operator Interface 2 1 1 2 2 2 4 The name of the variable is located in the upper left corner of the reading e g Speed The unit value of the displayed variable is located in the upper right corner of the reading e g RPM The unit value applies to the reading and the setpoint value if any The value of the variable is the largest displayed item in the reading it is displayed just below the variable name and unit value The layout of the lower portion of the reading depends on the currently active controller mode The lower portion of all readings is typically blank however additional items are displayed for the reading that pertains to the active controller mode For example the previous figure is the reading when the controller is currently in speed mode
42. the input impedance of each analog input the maximum voltage available depends on the value of the potentiometer Several examples are listed below Analog input functions for the throttle controller is discussed in Chapter 11 section 8 2 Dyn Loc V User Manual POT Value Voltage Range 10K Oto 9 660 volts 12K 0 to 10 207 volts 15K 0 to 10 819 volts 20K 0 to 11 509 volts 25K 0 to 11 968 volts Connector Summary 13 33 Chapter 13 Reference 4 2 3 THROTTLE CONTROL Type DB 37 male Signal Type Pin Description Error Output O 1 Error signal to actuator PAU Error Common 20 Ai Shield 2 Error signal shield Ai Reset O PLC 21 ACTON O PLC 3 ESTOP O PLC 22 From hardware ESTOP circuit Common 4 Pi PFAIL I PLC 23 PFAIL state from Throttle PAU Common 5 Pi PAU OK I PLC 24 24 volt supply I 6 1 of 2 pins At least one must supply power 24 volt supply I 25 1of2 pins At least one must supply power n c T n c 26 Analog Actuator Input I 8 Analog actuator position feedback signal Analog Actuator Common 27 Ai Shield 9 Analog actuator feedback shield Ai n c 28 n c 10 Common 29 Pi Common 1 Pi Button Up I PLC 30 Remote OCS button input Lamp Lower Limit O PLC 12 Remote OCS lamp output Button Down I PLC 31 Remote OCS button input Lamp Upper Limit O PLC 13 Remote OCS lamp out
43. to clear out all of these conditions If the root cause s of these conditions is no longer present the reset will succeed and the controller will now accept another enable request If the root cause s persist the reset will not be able to clear out all of these conditions and the controller still cannot be enabled The following digital inputs must be asserted in order to enable the dynamometer controller If not present an appropriate error message is reported e Master Enable apply 24 vdc to pin 16 of the GENERAL PURPOSE I O connector e PAUOK apply 24 vdc to pin 19 of the DYNO CONTROL connector Note The Master Enable input requirement can be overridden by setting the Ignore Master Enable Input property to Yes see Chapter 8 section 2 0 Initially the following digital inputs do NOT need to be asserted in order to enable the dynamometer controller however they must become asserted within a fixed number of seconds from when the controller is first enabled If not an appropriate controller fault is generated The action associated with each of these faults is configurable see Chapter 5 PAUON apply 24 vdc to pin 6 of the DYNO CONTROL connector within N seconds of onset of enable Coolant ILK apply 24 vdc to pin 18 of the DYNO CONTROL connector within N seconds of onset of enable The allowable time delay setting N for each of these input signals is listed in section 2 0 Controller Faults When en
44. 12 Digital Control Card System status and the status from one selected controller are continuously present on the digital outputs of the DIGITAL CONTROL connector The controller select bits i e the CS1 CSO input bits determine which controller status is output All output bits are summarized below Output s Status Type Description MD1 MDO Selected Controller Only Outputs the current controller mode for the selected controller Mode bits are listed in a table in section 4 1 2 ENABLED Selected Controller Only Output relay Closed Controller is Enabled Open Controller is Disabled CONTROLLER_FAULT OK to RUN Selected Controller Only System Output relay Closed Controller Faults exist Open No Controller Faults Output relay Closed when no Fault or ESTOP conditions exist Provides the same functionality as the corresponding Programmable Digital Output function see Chapter 8 section 5 1 ESTOPPED System Output relay Closed No ESTOP condition Open ESTOP condition exists RESET System Output relay Closed Dyn Loc V reset exists Open No reset condition Note Ifthe Controller Select bits are invalid or the selected controller does not exist all controller status output bits are set to zero i e the relays are open Dyn Loc V User Manual Operation 12 9 Chapter 12 Digital Control Card 4 1 4 Programming Tips The following progra
45. 2 jumper should be removed in order to prevent any on board calibration resistors from affecting the results Note The shunt calibration enable outputs are PLC style 24 vdc outputs Some external interfacing circuitry may be required if the shunt calibration enable inputs in the torque transducer require a lower input voltage Torque Feedback Dyn Loc V User Manual Chapter7 Transducers 2 5 2 Shunt Calibration Procedure The following procedures describe how to use the shunt calibration feature to check the existing span calibration for drift and to re span if necessary Storing Shunt Calibration Values The first step in the shunt calibration process is to perform a real calibration by zeroing and spanning the load cell as described in section 2 4 When done all spanning weights should be removed and the system re assembled into its normal operating configuration Shunt calibration values are stored as follows 1 Touchthe Shunt CAL On button to electrically add a resistive load to one side of the load cell bridge network A torque reading is displayed 2 Touchthe Store New Reading button to save the displayed positive shunt calibration value 3 Touchthe Shunt CAL On button to electrically add a resistive load to the other side of the load cell bridge network 4 Touchthe Store New Reading button again to save the displayed negative shunt calibration value Note Touch the Save button before exiting
46. 93 199 UNDEFINED Internal Software Errors 200 249 Internal software errors are generally due to programming errors in the Dyn Loc V They are intended to catch programming errors that occur during product development they should never occur in the final release of this product None of these errors are documented in this manual instead Dyne Systems should be contacted if an error code in this range is detected 13 26 Error Codes Dyn Loc V User Manual Chapter 13 Reference 4 0 Connector Summary All connectors on all Dyn Loc V back panel boards are described in this section The Type column indicates the type and direction of many of the signals The last column specifies which common i e power supply low side return path the specified common signal is connected to The symbols used e g P1 Ai etc are schematic references Schematics are only available to factory personnel The following notational conventions are used in the connector pinout lists Symbol Description n c not connected I Input O Output I PLC PLC style input Chapter 13 section 5 5 O PLC PLC style output Chapter 13 section 5 4 O Relay Dry contact relay output Pi Isolated PLC common Ai Isolated Analog Common Di Isolated Digital Common De Encoder Excitation Common Dyn Loc V User Manual Connector Summary 13 27 Chapter 13 Reference 4 1 Dynamometer Controller Back Panel The pin de
47. A 3 Reference Output 200 units 100 0 T 0 1 2 3 4 5 6 7 sec UP Ramp Rate 200 units sec DOWN Ramp Rate 200 units sec Figure 4 1 Ramp Rate Processing 4 2 General Controller Concepts Dyn Loc V User Manual 1 2 1 1 2 2 Chapter 4 Dynamometer Control Increasing the ramp rate value speeds up the system response to setpoint changes since the ramped reference output will reach the commanded setpoint value more quickly similarly decreasing the ramp rate value slows the system response to setpoint changes Note Highramp rate values only ensure the ramped reference which is input to the control loop will quickly reach the commanded setpoint The control loop if not tuned correctly and or the mechanical system may not necessarily be able to follow rapid changes in the ramped reference This issue is explained in section 1 4 Ramp Rate Units and Values The unit label for all ramp rate values is display units per second For example if speed is displayed in RPM the units for all speed ramp rate values are RPM sec Note Ifthe configured display units of any Control Variable CV is changed the ramp rate values for that CV will automatically be adjusted accordingly The following rules apply to ramp rate values e Qis not allowed else the ramped reference would never change 0 001 units second is the smallest allowable ramp rate Negative ramp rates are not allowed There is virtually no upper
48. A torque transducer can be re spanned by spanning to a previously stored shunt calibration value as described in section 2 5 2 Gain Correction Limits When calibrating the gain of any transducer the Dyn Loc V enforces a reasonableness policy on the final gain correction value The minimum and maximum allowable gain correction factors are 0 5 and 2 0 respectively When the Span button is touched and the resulting computed gain correction value falls outside of these limits the gain correction value is truncated to the appropriate limit and a warning messages is displayed on the front panel message line Gain correction values should always be at or near 1 000 Excessively large or small gain correction values are most likely caused by transducer damage and or improper transducer setup parameters The imposition of gain correction limits prevents attempts to calibrate out these types of errors Reset Touching the Reset button clears all existing calibration values i e Offset and Gain Correction Values This button is useful if mistakes are made during the calibration process i e the transducer is zeroed and or spanned to an invalid and possibly ridiculous value Shunt Calibration Shunt calibration is a feature used to check the span and if necessary re span a load cell without having to disassemble the test stand and re attach the spanning weights Shunt calibration adds weight electrically to a load cell by switchin
49. AA 23 Control Variable csosessisregad asas pp ema RIMAS AR AS 23 D A Converter and Output Filler i122 2322s peRr RE RIP RAS RE YO 23 Dyn Loc V User Manual TOC 3 Table of Contents Anti Alias Filter and A D Converter oo ooooooooooomoomooooo 23 Frequency Measurement Logic sans vaso e e desta Das SEA seve ds 23 BEC PAU 2 bcunteroiitatirosipar cara brasier bed 23 Chapter 5 Faults Controller Faulis cria tar ra pies a E A DA a ERN 1 Controller Paul ACUOUS ccensce ceded pieghle ss peras ble bordes 2 Dynamometer Controller Fault Actions ope pr Rs 2 Throttle Controller Fault Actions 0 40 28 Exe ead dea kn ra a Y 3 Ignotus Fault Actions sess s ei REA EEerPreabEoR hoaia oo aaa 3 Controller Fault State es asha DEVER arb eco Rp SI ea ERR Ado ea ra 3 FAUNA eM Cr 4 Ciara Pauli 2 06 600c0de huge sario sheeiet dsidedaeestiededd canes 4 Chapter 6 Tuning J nt s Parameters ques pps ries ed atra bae TD VE eases 2 uude tm PRPPRERCC Tr PETITTT 3 Tuus Page Display o ace syne eae wr yee aes EA PSI AtS 3 Graphical Tinie Page reo a ERES eee See da 4 Tes SEC PTT ELIT 7 Peed Forward Control aces dus ep P gabe AMNES oes Gab dod a eA cd du aes 7 E COMPUALON sap AA Ded ese 8 K gt K and K TUNNE parada 8 Chapter 7 Transducers Speed Feedback 24 2522 pitiriasis ir SK 1 Dep Parameters rrr 1 Magneto Pickup MAG PU cose ses py ERAT EAR P YE RARUS 3 SOU ga sadio ehe saw Pd uet Ra Fanta ere dst EQ ie Vates ax Po 3 lo
50. By Wire position and speed control Software Based Design All major controller functions are implemented in software allowing new features to be developed and easily deployed throughout the life of the product Object Oriented Design Controller objects feedback signal objects fault objects etc make the Dyn Loc V easy to configure since all parameters are organized in an intuitive manner Chapter1 Introduction Configurable General Purpose I O Each Dyn Loc V has 15 Programmable Digital Outputs 5 Programmable Digital Inputs and 3 Programmable Analog Outputs Security Configuration tuning and calibration security is available The main operator has complete control over which of these features is available to other operators PLC Compatible Digital I O All digital inputs and outputs are standard 24 VDC PLC style inputs and outputs Optical Isolation All inputs and outputs are optically isolated to improve overall system reliability Hardware ESTOP All Emergency Stop ESTOP functionality is implemented entirely in hardware no computer intervention is required to shut down the test system 2 0 Interfaces 2 1 2 2 2 3 1 2 Front Panel The Dyn Loc V front panel is the main operator interface The front panel contains an active matrix LCD display a touch screen and a membrane keypad All functionality of the Dyn Loc V can be accessed and or controlled from the front panel The front panel Operator In
51. Digital Control back panel board DS607 board are described in the sections that follow The functions of each input and output as a complete set are configurable based on the type of device providing the digital control The Digital Control feature is described in Chapter 12 4 4 1 DIGITAL CONTROL Type DB 25 male Note The Digital Control feature is a purchased option Signal Type Pin Description Input 1 I PLC 1 Input 2 I PLC 14 Function of Inputs 8 are configurable Input 3 I PLC 2 as described in Chapter 12 Input 4 I PLC 15 Input 5 I PLC 3 Input 6 I PLC 16 Input 7 I PLC 4 Input 8 I PLC 17 Input Common 5 Common for all inputs Input Common 18 e ue Oe Input Common 6 mene Loopback IN 19 Loopback for cable off detection by host Loopback OUT 7 Loopback for cable off detection by host Output 1 O Relay 20 Output 2 O Relay 8 Function of Outputs 1 8 are configurable Output 3 O Relay 21 asdescribed in Chapter 12 Output 4 O Relay 9 Outputs are dry contact relay outputs Output 5 O Relay 22 Output 6 O Relay 10 Output 7 O Relay 23 Output 8 O Relay 11 n c 24 n c 12 Output Common 25 Common for all relay outputs Output Common 13 Md i Dyn Loc V User Manual Connector Summary 13 37 Chapter 13 Reference 5 0 Electrical Specifications 5 1 5 2
52. Dyn Loc V controller includes a multi point torque calibration feature All calibration weights sets of weights calibration arm lengths and expected torque readings are managed by the controller Since all information is entered and verified one time during initial configuration no additional calculations are required at calibration time This not only eliminates errors but also reduces the time required to complete each calibration session A brief feature summary of the multi point torque calibration feature is listed below Manage up to eight certified weights weight values and serial numbers Manage up to eight weight sets Store up to eight calibration points per calibration arm plus a zero point i e seventeen total points Generate a calibration report file This feature is fully described in a separate document Contact DyneSystems for a copy of the Multi point Torque Calibration guide Torque Feedback Dyn Loc V User Manual 2 7 2 7 1 Chapter7 Transducers Estimated In Line Shaft Torque In many applications it is absolutely necessary to control and display in line shaft torque i e engine torque instead of the dynamometer reaction torque measured by a typical load cell This is usually accomplished by installing an in line torque transducer to the output shaft of the engine but unfortunately the use of an in line torque transducer is often not feasible due to its relatively high cost The Dyn Loc V pr
53. EOIPPbaPqEE voa una RES 39 Main DYSisEo8 V EHTRR de V EQUES HUE RE ees SEP PEE Lu RO 39 Front Panel Interface Firmware 2 d4 ss e 4E e ny dd ga 39 Hardware Informations 4 02 65o6t2e hates seedsee sede SER RIAM REOS 39 CPU TYPE EP c 39 Electronically Programmable Logic Devices ooooooomoomoo o 40 Constants and COnversi dS eenbicridarirarisar irc ay boares Pass 41 A MEE UE da DE 41 Conversion Pachors xs quer iaa VR RO dE SG NG 41 JACEOILVNIS 225922499999 S4APOD ards hie P REO cides bas e ess ideias 42 sac esse as acute one icit Donee pt ieee nile pd ead oa or ues 43 Dyn Loc V User Manual TOC 9 Table of Contents TOC 10 Dyn Loc V User Manual Chapter 1 Introduction The Dyn Loc V is a digital eddy current dynamometer controller Each Dyn Loc V contains a main computer general purpose I O interfaces and a power supply An optional throttle controller can be added to the Dyn Loc V to provide a complete engine testing platform 1 0 Standard Features Speed and Accuracy All control loops are updated 500 times per second providing fast and accurate control Powerful Operator Interface The format panel interface presents two sets of virtual lever wheel switches providing quick and efficient set point entry and setpoint adjustments Feedback Signals Control standard speed torque and throttle position Throttle Control Option Control position of a throttle actuator or control your device using direct
54. Full Scale Value and Load Cell Radius parameters Chapter 7 section 2 1 NOTES All analog torque voltage values are calibrated values Power Analog value of the computed power reading Scaling 1s fixed at 100 HP volt Ramped Reference Cell Assistant Analog ramped reference input to the PID control loop Scaling depends on the controller mode For example if controller is in speed mode scaling of this programmable analog output is the same as the scaling for a Speed programmable analog output listed above Similarly if the controller is in torque mode the ramped reference programmable output is scaled the same as a torque programmable output listed above Selecting this source allows Cell Assistant running on a host computer to control this output voltage The Dyn Loc V Cell Assistant driver provides three analog output channels allowing a running TestPlan to set the voltage of each programmable analog output Constant Voltage Output a constant voltage The magnitude of the output voltage is determined by the Offset Correction value listed in section 4 1 1 Dyno Error Provides another Dyno Error Output signal identical to same on Pin 1 of the DYNO CONTROL connector see Chapter 13 section 4 1 4 Dyn Loc V User Manual Controller Hardware 4 13 Chapter 4 Dynamometer Control The following additional sources are available for the analog outputs on an optional throttle co
55. Issuing Commands The function of each momentary push button is listed in section 3 2 2 The functions are self explanatory All inputs are edge triggered such that the appropriate controller command is issued at the onset of the button press Reading Status The digital outputs annunciate the enable disable status and mode status of the respective controllers The definition of each output is listed in section 3 2 2 Dyn Loc V User Manual Operation 12 11 Chapter 12 Digital Control Card 5 0 Fuses F1 Install a 1A fast acting fuse BUSSMAN GMA 1A This fuse limits the total current that can flow through all eight of the dry contact relay outputs on the DIGITAL CONTROL connector 12 12 Fuses Dyn Loc V User Manual Chapter 13 Reference 1 0 Setup Parameter Hierarchy This section contains a comprehensive listing of all configurable parameters in the Dyn Loc V The list contains an example of one dynamometer controller and one throttle controller The factory default value o r Dyn Loc V O Status ACTIVATED feach parameter is listed F Control Variables 0 Display Resolution 1 1 Display Units RPM 2 Display Filter 1 Description DYNO Controller 2 Active Parameter Set Number 0 3 Calculated Power Units HP 4 Calculated Power Display Resolution 1 10 Hard Over speed Limit 0 0 RPM 11 Hard Over torque Limit 0 0 LB FT 12 At Spee
56. ON OFF Select Provides external digital control of the ON OFF state of the dyno controller Digital control is described in Chapter 4 section 6 0 Digital Control Torque Speed Select Provides external digital control of the operating mode of the dyno controller Digital control is described in Chapter 4 section 6 0 Shaft B Select Ifthe dyno controller is configured for selectable dual shaft operation switch the controller to shaft B operation when this input is asserted Dual shaft operation is discussed in Chapter 4 section 1 9 7 0 ESTOP 7 1 7 1 1 7 2 8 8 The GPIO card implements a completely hardware ESTOP chain Dyno and throttle controllers perform intelligent processing at the onset of an ESTOP however in the event of a CPU failure the hardware ESTOP chain is also wired directly to all attached power amplifier units Each PAU can then perform its own ESTOP processing ESTOP Inputs The following ESTOP input sources must be valid at all times otherwise the ESTOP chain is broken resulting in an ESTOP condition The ESTOP switch on the Dyn Loc V front panel must be closed The ESTOP switch on the optional Throttle Controller front panel must be closed ESTOP input on pin 17 ofthe GENERAL PURPOSE I O connector must have 24 vdc applied CPU watchdog circuit must be regularly updated by the main computer Main computer can break the chain at any time to generate a software generat
57. Offset 0 0000 LB FT Gain 1 0000 Figure 7 1 Torque Calibration Page 1 Sided or 2 Sided Calibration A torque transducer must always be zeroed however it can be spanned in one and sometimes two directions Many test stands are physically capable of hanging weights and hence spanning in only one direction In this case the Calibration Type parameter should be set to Zero 1 Sided Span It makes no difference if the span direction produces positive or negative torque readings During normal operation the Dyn Loc V will continuously apply the same gain correction value to all torque readings Some test stands are capable of hanging weights and hence spanning in two directions In this case the Calibration Type parameter should be set to Zero 2 Sided Span The calibration page will automatically adjust the proper gain correction value positive torque gain correction or negative torque gain correction based on the sign of the incoming torque readings Similarly during normal operation the Dyn Loc V will continuously apply the proper gain correction value positive or negative to all torque readings based on the instantaneous sign of the readings Torque Feedback Dyn Loc V User Manual Chapter7 Transducers 2 4 2 Procedures The overall calibration procedures for 1 sided and 2 sided calibration are summarized below Several of these steps are explained in greater detail in the sections that follow O
58. R is connector on the back ofthe Dyn Loc V Connecting a host connected to an computer to one ofthe OCS connectors is not allowed The OCS port UART on the host computer may get damaged because pins 6 and 9 of each OCS connector are part of the hardware ESTOP chain and will present a DC voltage of 24 volts across these pins 152 159 UNDEFINED Communications Errors 160 169 These errors are typically due to bad cabling bad shielding and or severe electrical noise Error Code Text Description 160 Packet checksum Command packet is corrupt error 161 169 UNDEFINED Hardware Configuration Errors 170 179 These errors are boot errors and must be corrected before the Dyn Loc V accepts controller commands Error Code Text Description 170 UNDEFINED 171 Controller The Dyn Loc V has detected a controller card that is missing an addressing address jumper and or an interface cable Check all installed problem controllers repair as needed and reboot the Dyn Loc V 13 24 Error Codes Dyn Loc V User Manual Chapter 13 Reference Error Code Text Description 172 GPIO card The UART on the GPIO card i e DS605 board was not detected RS 232 UART The card is either missing or damaged Repair and reboot the not found Dyn Loc V 173 Configuration The version number of the Dyn Loc V parameters stored in version newer non volatile memory is newer than the version number o
59. Rate setup parameter see section 3 1 1 Itis always set to 115 Kbaud and should not be changed The remaining UART settings are 8 data bits 1 stop bit no parity and no handshaking These settings cannot be changed 3 1 1 Setup Parameters The following setup parameters pertain to the COMPUTER port Path WDyn Loc V System Computer Port ID Parameter Values Description O UART Baud Rate 115200 Sets baud rate of host COMPUTER 57600 connection Default value is 115200 and 38400 should not be changed 19200 9600 Changes occur after next power cycle 3 2 4 0 4 1 OCS Connections The OCS connections are reserved for use by external and or remote front panel displays Network Connections NETWORK Connection This connector is used to connect the Dyn Loc V to a host computer A standard straight thru network cable is required to make a direct connection from the Dyn Loc V NETWORK port to a host computer If the NETWORK port is connected to a hub or switch a cross over cable is required Or the hub switch must have auto MDI MDI X cross over detection functionality which is a common feature of most modern switches If so a typical straight thru cable can then be used The Dyn Loc V uses a static IP address that is configurable Dyn Loc V User Manual Network Connections 8 3 Chapter8 General Purpose l O Card 4 2 Setup Parameters The following parameters pertain to the NETWORK port Pa
60. SSMAN GMA 24A This fuse limits the total current the PLC outputs on the GENERAL PURPOSE I O connector can draw from the internal 24 vdc supply 8 10 Fuses Dyn Loc V User Manual Chapter 9 Security Setup Calibration and Tuning are secured features in the Dyn Loc V Each can be individually secured giving the Dyn Loc V administrator total control over which features are available to an ordinary operator Setup Parameters All security parameters and their location are listed below Path WDyn Loc V System Security Description Values Description Secure Mode On Off Displays the current security state of the system Must be set to On to secure selected features Password id Existing password Consists of 4 to 10 digits Factory default 1234 Secure SETUP Yes always Access to SETUP parameters is always secure when Secure Mode is set to On Secure CALIBRATION Yes No Selects if calibration feature is secured when Secure Mode is set to On Secure TUNE Yes No Selects if tuning feature is secured when Secure Mode is set to On Powerup Secure Mode On Off Initial security state of the Dyn Loc V at power up Chapter9 Security 2 0 Accessing a Secure System To access a secure system follow the procedure listed below 1 Press SETUP 2 Touch the Dyn Loc V selection button The Enter Password dialog box is displayed Enter P
61. The reading displays the current setpoint value in parentheses located in the lower right corner It also displays the LOCKED status in the lower left corner Controller locking is discussed in Chapter 4 section 1 4 Background Colors The background color of the reading provides additional information White Default background color for all readings Yellow A yellow background indicates an enabled controller The reading that pertains to the active controller mode will change from white to yellow when the controller is enabled Lever Wheel Switches The upper right portion of the main screen contains two sets of virtual lever wheel switches Lever wheel switches provide a powerful method for an operator to manually issue setpoints to the controller Two unique setpoints are maintained for each controller mode i e speed and torque allowing an operator to easily alternate between the two setpoints while the controller mode remains constant Also quick incremental changes to a single setpoint can be issued using either set of switches A single set of lever wheel switches is shown below NL Touch to Send Touch to Scroll Digit Values As shown above each individual digit provides two hot spots When touched the value of the respective digit scrolls up or down Each set of lever wheel switches function similar to an Main Controller Screen Dyn Loc V User Manual 2 3 2 4 Chapter 2 Operator Interface
62. This is a transient problem that occurs after a setpoint change Eventually the control loop and mechanical system catch up and reach a steady state causing the LOCKED indicator to turn on again If desired the ramp rate values should be reduced in order to maintain the LOCKED status during setpoint transients Aggressive tuning parameters The entire system is capable of responding to fast changes in the ramped reference however the system badly overshoots the commanded setpoint due to overly aggressive tuning parameters Tuning is discussed in Chapter 6 If re tuning is not desirable reduce the ramp rate values to dampen the system Poor tuning parameters The control loop is not able to stabilize the controlled variable Due to oscillations the controlled variable continuously overshoots and undershoots the commanded setpoint value The control loop must be re tuned as described in Chapter 6 General Controller Concepts Dyn Loc V User Manual 1 5 1 6 Chapter 4 Dynamometer Control De Activating a Controller In addition to being installed a controller must also be activated in order to function All controllers default to the active state when initially installed however it may occasionally be desirable to de activate a controller for one or more reasons A few examples are listed below When the optional throttle controller is installed mode conflict detection prevents either controller from running in torque mode unl
63. Type parameter to Load Cell This section also lists additional parameters pertaining to load cell configurations that should be set as needed Specifically the following load cell parameters MUST be set Load Cell Full Scale Value Load Cell MvV Load Cell Radius In Line Torque Sensor Wiring Note Some in line torque sensors are really load cell type devices and thus should be wired and set up as described in section 2 2 Setup A torque sensor configuration is selected by setting the Transducer Type parameter to Torque Sensor This section also lists additional parameters pertaining to torque sensor configurations that should be set as needed Specifically the following torque sensor parameter s MUST be set Torque Sensor Sensitivity Dyn Loc V User Manual Torque Feedback 7 7 Chapter 7 Transducers 2 4 Calibration All torque transducers must be calibrated on a regular basis The torque calibration page is shown below in Figure 7 1 Chapter 2 section 3 2 describes how to access this calibration page for all installed torque transducers Note The Calibration Type 1 Sided or 2 Sided must be selected prior to calibrating the torque transducer since this selection affects the operation of the torque calibration page 2 4 1 7 8 Messages PO Save Done Shunt Calibration Previous Shunt CAL On Shunt CAL On Store New Reading OFF Correction Factors
64. U OK input pin Loss of PAU ON 24 vdc is no longer present at pin 6 of the DYNO CONTROL connector An external PAU is typically wired to this input pin Whereas the PAU OK input pin is used to generate a fault due to PAU hardware failures the PAU ON input pin can be used to generate a fault for other non hardware related PAU failures Loss of Coolant ILK 24 vdc is no longer present at pin 18 of the DYNO CONTROL connector This input is typically used to provide an indication of acceptable coolant flow pressure and or temperature Dyno Power Limit Exceeded This fault is thrown if the dyno power exceeds 10046 of the rated dyno horsepower for more than 5 seconds The fault is immediately thrown if the dyno power reaches 200 of the rated dyno horsepower The 10096 dyno power value is specified by the Dyno Rated Horsepower setup parameter see section 3 0 Wrong Direction This fault is thrown if the rotating shaft turns one half of a complete revolution in the negative speed direction Allowing a half revolution to occur without a fault permits systems with some backlash in the mechanical connections to start without error Clearly a direction sensing encoder is required 1 e NOT a MAG PU Controller Operation Dyn Loc V User Manual Chapter 4 Dynamometer Control 6 0 Digital Control 6 2 1 6 2 2 Digital control of the dynamometer controller is available via the use of two progra
65. U TYPES pras Rer CR ERE E E RAN RUE REM EE RA 4 DION AEE EE AA EEE E E 4 MD so snse se ees a TRIES EP Ae eein ana E gage 5 S aeee 6 SINE 2s auo Pat oues ees Plc T atta ws apes ub b aui S etu ag 6 Saving Setup Pardinelersss 44iine os sesivas cocina rinden 8 Backing Up and Restoring Setup Parameters 2 2 22 cose ots 8 Top Structure of the Setup Tree 2 4 2 sues oe EE EX RR ER PIE 9 Expanded Top Structure of the Setup Tree 22222 sss b e eie be 10 Chapter 4 Dynamometer Control General Controller Concepts qu au zx RES Ix Rer Ax P eae Sees E 1 Master and Computer Modes csssasisssigasfeo ssa ieaseneshuceivas 1 Ramp RAES wars AR H m 2 Ramp Kate Units and Values oscuros sk EX E44 ERAT CX REG Y Sa 3 Up Down Ramp Rates and Master Computer Ramp Rates 8 TOC 2 Dyn Loc V User Manual Table of Contents Bhruplass TOIOSTELS sds dove Co ada e ra tee er dor wea mod ir 4 Locked Stas ss xod atate rex ir ma devas eras SOC RE SUC ewan d d 4 De Ac vatme a Controller e 2222252429 terreas S DIEA A etaria opa e de 5 ES OP ACen suado E Ip IS Da a eee E EOS WS 5 BSIOD ACUON asas wees obese Ney Shay RE e RE as os SEQ Hane odes Shes 6 4 Duattant Operations i0cii0cei deletes iterna EX dade sisal bro sds 6 Du al Shaft Operation sagas id peg gx ede RO Yat RS 4 a eee oe es 7 Shaft Selection SOUICES 2 4 lt 224 i458 Foss Meas EP DS Fede yore ss 7 Shaft Change RestriclonS lt esipevic
66. abled the dyno controller continuously checks for incorrect faulty and or dangerous input conditions When any of these conditions occur the dyno controller will throw a fault The Controller Operation Dyn Loc V User Manual Chapter 4 Dynamometer Control controller actions that occur in response to each fault are programmable A typical fault action is to disable the controller and generate an ESTOP Available fault actions and fault setup is discussed in Chapter 5 When one or more faults are thrown the fault indicator on the front panel will glow bright red Fault indication and a procedure for viewing existing fault conditions is discussed in Chapter 2 section 4 5 Note Fault conditions are latched they only can be cleared by pressing the RESET button If fault conditions still persist they are re thrown Dynamometer Controller Faults Path Dyn Loc V Faults Fault Description Hard Over speed The absolute value of the speed reading has exceeded the value specified in the Hard Over speed Limit setup parameter see section 2 0 Hard Over torque The absolute value of the torque reading has exceeded the value specified in the Hard Over torque Limit setup parameter see section 2 0 Loss of Speed Feedback LOSF A zero speed reading was detected while the controller was enabled This is most likely caused by a broken and or disconnected speed sensor LOSF is a potentially dangerous run away
67. ain screen The contents of the fault list dialog are discussed in section 4 5 Message Line The message line displays error messages and other notifications from the Dyn Loc V Most errors are caused by erroneous input data e g invalid setpoint values invalid configuration values etc Notifications on the other hand can appear at any time and are not necessarily caused by any recent operator input Each message provides an error number and appropriate error text A comprehensive list of error messages is presented in Chapter 13 section 3 0 The message line is cleared when the RESET button is pressed The message line is also a button When touched a message list dialog pops up over the main screen The contents of the message list dialog are discussed in section 4 6 Dyn Loc V User Manual Main Controller Screen 2 5 Chapter 2 Operator Interface 2 5 2 6 2 6 Setpoint Entry The Setpoint entry edit box displays setpoint digits as they are manually entered from the keypad Once entered the setpoint can be immediately issued to the controller by pressed the ENTER keypad button as described in section 4 2 Alternatively the entered setpoint can be loaded into either of the sets of lever wheel switches by pressing the respective SET keypad button as described section 4 3 Ramp Rates The Ramp Rate button displays the present values of the up and down ramp rates for the active mode of the controller The up
68. al Chapter3 Setup Basics Press the Up and Down arrow keys to toggle between the two available values Touch the OK button to accept the parameter change touch the Cancel button to quit without making any changes Note The ENTER and CANCEL keypad buttons duplicate the function of the OK and Cancel touch screen buttons 1 5 2 Number This data type is a decimal number The allowable range and decimal precision depends on the specific parameter The following figure shows the pop up dialog for modifying number data types The parameter name is displayed in the upper left corner of the dialog pooo Press the numeric keys to enter a new value Press the Left arrow key to erase the previously entered digit or press the CANCEL button to erase all previously entered digits Touch the OK button to accept the parameter change touch the Cancel button to quit without making any changes Note The ENTER and CANCEL keypad buttons duplicate the function of the OK and Cancel touch screen buttons The CANCEL button must be pressed twice the 1st press clears the entered data and the 2nd press dismisses the dialog box Dyn Loc V User Manual Dyn Loc V Setup Parameters 3 5 Chapter3 Setup Basics 1 5 3 1 5 4 3 6 List This data type can have one of several values that can be selected from a list of allowable values The following figure shows the pop up dialog for modifying list data types The parameter name is displayed in the u
69. applies to systems getting their actuator position feedback from a throttle position sensor or an analog actuator position potentiometer 134 Gain correction While calibrating a transducer the computed gain correction truncated to value is too large and has been reduced to the maximum MAX value allowable value See Chapter 7 section 2 4 4 for more information 135 Gain correction While calibrating a transducer the computed gain correction truncatedto MIN value is too small and has been increased to the minimum value allowable value See Chapter 7 section 2 4 4 for more information 136 148 UNDEFINED Dyn Loc V User Manual Error Codes 13 23 Chapter 13 Reference Error Code Text Description 149 Calibration database is full Multi point torque calibration allows 8 calibrations points on each side of the calibration arm Any attempt to create additional calibration points will result in this error message Cable Connection Errors 150 159 These errors are displayed when there are incorrect cable connections between the Dyn Loc V and one or more front panel displays Error Code Text Description 150 A front panel is All front panels must be connected to one of the three OCS connected tothe connectors on the back ofthe Dyn Loc V Do not connect a front host panel to the COMPUTER port COMPUTER port 151 Host A host computer must be connected to the COMPUTER COMPUTE
70. arranty on the use ofthe equipment in combination with other products or in the practice of any process and if a claim suit or action is based thereon Buyer shall defend indemnify and save Dyne Systems harmless therefrom LIMITATION OF LIABILITY Dyne Systems liability for defective or nonconforming products whether based on breach of warranty negligent manufacture or product liability is exclusively limited to repair or replacement at Dyne Systems election of such products Dyne Systems assumes no risk and shall be subject to no liability for any damages or loss resulting from the specific use or application made ofthe Products Dyne Systems liability for any other claim Dyn Loc V User Manual Product Warranty 13 43 Chapter 13 Reference whether based on breach of contract negligence or product liability relating to the products shall not exceed the price paid by Buyer for such Products In no event will Dyne Systems be liable for any special incidental or consequential damages including loss of use loss of profit claims of third parties or damages arising from bodily injury or death however caused whether by the negligence of Dyne Systems or otherwise EQUIPMENT MADE BY OTHERS Any items supplied that are not manufactured by Dyne Systems are covered by the original manufacturer s warranty and not by a Dyne Systems warranty BUYER SUPPLIED PRODUCT Dyne Systems accepts Buyer provided equipment as a courtesy only Dyne Systems
71. assword H Cancel 3 Enter the password using the numeric keypad buttons and touch OK If the entered password is correct the Dyn Loc V main setup page will be displayed Note The factory default password is 1234 If the security feature is going to be used the default password should be changed to a more secure value as soon as possible Note Ifthe existing password is misplaced or forgotten contact Dyne Systems When the previous procedure has been successfully completed the Dyn Loc V is no longer in secure mode The operator has full access to all Dyn Loc V features including setup parameters calibration and tuning When all changes have been made the Dyn Loc V can be re secured as described in section 2 2 9 2 Accessing a Secure System Dyn Loc V User Manual Chapter 9 Security 2 1 Changing the Password When a password modification is attempted the Dyn Loc V displays the following dialog box EN Do Enter the current password and press ENTER Enter the new password It must be a 4 to 10 digit number Press ENTER Enter the new password again in the Confirm field Touch OK A O N a Note When done touch the Save button on the main setup page to guarantee that the new password is saved in non volatile memory Dyn Loc V User Manual Accessing a Secure System 9 3 Chapter9 Security 2 2 Securing the Dyn Loc V The Dyn Loc V security feature can be re enabled as follows Set the Se
72. ation setup modes when the UP and DOWN buttons are pressed Nine move rates are available where move rate 1 is the slowest and move rate 9 is the fastest Touch the up arrow and down arrow buttons to adjust the move rate as needed Direction Changes the direction of actuator rotation when going from 0 to 100 actuator position The direction of actuator rotation is typically changed by modifying the value of the Actuator Direction parameter see section 6 1 A direction button was also added here for the convenience of operators that frequently change the mechanical setup of their actuator Setup Buttons and Progress LEDs The upper right corner contains the actuator setup buttons UP DOWN ENTER and SOFT SHUTDOWN and setup progress LED s UPPER LIMIT LOWER LIMIT ACCEPT LIMIT and FAULT The availability and function of each of these components depends of the selected setup mode Each is discussed in greater detail in the calibration procedure sections that follow Note The layout of the setup buttons and setup progress LED s on this calibration page is identical to the same on the Dyne Systems Remote Station box The functionality is also the same making the calibration procedure identical for both the Local and Remote Station setup modes Calibration Procedure During normal operation ofa throttle controller the movement range ofthe actuator is restricted to all positions between and including the 0
73. ault State The controller fault state is set to TRUE when any controller fault occurs The controller fault state essentially becomes the logical OR of all controller faults The controller fault state is reported on the Dyn Loc V front panel as well as to any connected host computer The fault state of each controller can also be output on one or more programmable digital outputs see Chapter 8 section 5 0 and thus be wired into external error processing and or system shutdown logic When the fault state of a controller is TRUE the controller cannot be enabled A reset is required to clear the internal controller fault state Dyn Loc V User Manual Controller Fault State 5 3 Chapter5 Faults 4 0 Fault List The Dyn Loc V front panel displays a time ordered list of all faults that occur The first fault in the list typically provides the most information concerning the root cause of a problem since other faults may be thrown as a result of the initial fault condition The fault list is discussed in Chapter 2 section 4 5 5 0 Clearing Faults All controller faults as well as the controller fault state is cleared when a reset is issued A reset can come from the Dyn Loc V front panel see Chapter 2 section 3 1 a host computer running Cell Assistant see Chapter 10 or the Reset input on the GENERAL PURPOSE I O connector 5 4 Clearing Faults Dyn Loc V User Manual Chapter 6 Tuning Speed and torque control in
74. back from the TPS connector If no TPS sensor is installed the position command voltage should be wired back in to the TPS connector in order to produce a position reading Control Output Types Dyn Loc V User Manual 5 3 5 4 Chapter 11 Throttle Control Position Cmd gt Motor Internally to the Dyn Loc V this configuration is identical to the Position Cmd gt ECM configuration described above in section 5 2 This selection item is simply more descriptive of the actual configuration In this configuration the by wire position command output is wired to the torque command input of an AC or DC drive The speed one direction only and torque of an electric motor can now be controlled in the usual manner The following parameter settings are required to properly configure a throttle controller for by wire control of an electric motor The Control Output Type parameter must be set to Position Cmd gt Motor Repeatall ofthe other settings as described in the previous section Note In this configuration Position mode corresponds to controlling the torque command to the AC or DC drive This is safe to do as long as some form of speed control is also present Mode and Enable Conflict Detection section 9 1 checks for the existence of speed control and for the purposes of Mode and Enable Conflict Detection Position mode is treated as a Torque Equivalent Mode Position Cmd gt Motor 4 Quadra
75. button When initially touched the P I and D buttons will turn YELLOW for 5 seconds This 5 second time window defines the UNDO period If you hear see and or sense instability caused by the newly entered value simply touch the button again while it is still YELLOW and the previously entered value will be restored If the 5 second time window expires or you begin to enter other values the newly entered tuning value will persist The amount of filtering applied to the feedback signal can be adjusted by touching the Filter button A pop up dialog will be displayed presenting several feedback filter selections Touch the desired selection to dismiss the dialog The filter selection dialog is shown below Dyn Loc V User Manual Tuning Page Display 6 5 Chapter6 Tuning Stopping the Waveform At any time the displayed waveform can be paused by touching the Scope button When ready touch the Scope button again the resume waveform updates Save Button The Save button should be touched as needed during the tuning session Two sets of data are saved when this button is pressed PID tuning values are permanently stored in the Dyn Loc V Xand Y axis settings as well as the pre defined setpoint values are stored locally with the front panel settings Note The front panel computer stores a unique set of X and Y axis settings and pre defined setpoint values for each tunable controller mode i e speed torque etc
76. caling to that of the external controller For example when using by wire speed control Kff is computed as follows REM Input Dynamic Range 10 ASI UT TEN Jf RPM Volt of external speed controller The RPM Input Dynamic Range is set when configuring a speed transducer see Chapter 7 section 1 1 K K and K Tuning Tuning is typically not required when using feed forward control The assumption is the external device accepts the speed command voltage from the Dyn Loc V and provides the necessary speed control thus the basic PID tuning parameters i e Kp Ki and Kd are all set to zero Only the feed forward element Kf is non zero Exception If the external speed controller provides poor speed regulation and or is really not a speed controller at all the Dyn Loc V can still provide speed control by adding a small amount of integral gain i e setting Ki to some small non zero value Kp and Kd should still be set to zero Feed Forward Control Dyn Loc V User Manual Chapter F Transducers The Dyn Loc V can interface with a variety of speed and torque transducers There are several tasks associated with installing and using any transducer e Correctly wire the transducer to the proper connector Setall appropriate setup parameters to properly configure and scale the feedback readings Calibrate the transducer The sections that follow discuss each of these tasks for a variety of transducers 1 0 Sp
77. ccept commands from the front panel When in Computer mode a controller will only accept control commands from a host computer connected to the COMPUTER port on the back of the Dyn Loc V box This feature is intended to give a host computer a higher priority over front panel operation Whenever a control command arrives from a host computer the controller is automatically switched to Computer mode Subsequent control commands from the front panel will be rejected In order for the controller to accept control commands from the front panel the front panel or the host computer must specifically command the controller to return to Master mode This usually requires a simple but deliberate button push on the front panel by an operator Chapter 4 Dynamometer Control 1 2 Ramp Rates The term ramp rate refers to the speed at which the control loop processes a commanded setpoint Every setpoint command is processed as shown in Figure 4 1 The ramp rate processor receives setpoint commands and gradually slews i e ramps the ramped reference output value towards the commanded setpoint value at a predetermined rate 1 e the programmed ramp rate The ramped reference output value and not the commanded setpoint is then input to the control loop Operator Commands New Setpoints Here Y Y Y 200 units 100 0 T 0 1 2 3 4 5 6 7 sec Setpoint Ramp Rate Processor Input Nine P y
78. ce that will be applied during an ESTOP 4 10 Controller Setup Parameters Dyn Loc V User Manual Chapter 4 Dynamometer Control 3 0 Dynamometer Setup Parameters The following properties of the eddy current dynamometer should be properly set as needed At minimum the rated horsepower should be set in order to protect the dynamometer by preventing the operator and or automation software from operating the dynamometer outside of its safe operating range Path WDyn Loc V Dynamometer ID Parameter Values Description O Dyno Rated 0 0 Specifies the maximum power the dyno Horsepower can safely absorb See description of the Dyno Power Limit Exceeded fault in section 5 2 for more information 1 Dyno Inertia 0 0 Dyno inertia for estimated in line torque calculation see Chapter 7 section 2 6 2 Dyno Inertia Units slug ft Units for entered dyno inertia above lb ft kg m 3 Eddy Current 0 0 Units are the same as configured for the Dropout Speed speed reading Chapter 7 section 1 1 Below this speed the control loop begins to discharge the integrator Provides smoother operation at low speeds since the eddy current dyno can no longer produce sufficient torque to maintain control 4 0 Controller Hardware 4 1 Programmable Analog Outputs Each controller dyno and throttle provides three general purpose programmable analog output signals Each analog output signal is available on th
79. ceso resas nets maannos ai nease a raene 19 Soft Over spee Detectioll iu sah Ged dw Ve m tor ai E I eee 20 Theory of Operation 4 5 oae ox reReE vidas PEE Eee x ud x RR DEM Een dues 21 Dyn Loc V User Manual TOC 7 Table of Contents Chapter 12 Digital Control Card oca A axe 1 Instala ar iba dd a 2 Selecting an Interface Configuration crac porra 2 Setup Pardes oc esce enda cur e eO apaga ROS EO dE ns 2 Interface Configuration TIPOS sss px Ee D ec RR Rel 3 Computer Control ree sessir ser XE VIR PRESSURE PIECE SEGA EE 3 P sh Button Control ass serio sas 10999 99 PESE OX EY ber E dH 4 A Saeed weds a desde Sad cedida ads 5 General WINS gt gt cts A 5 Computer Control WINE oo lt 2492 dito erp pessoas ER IER EHE des a Push Button Control Wiring crsco birria 6 Opera soci San EEE AAA Sd que E pad 7 Computer Control Op ration ss 425922 og xb ERU suse datg E ER ENS bys 7 Enabling the nterface Lasst DES bet RR RATED be 7 Issumg Commands su ser bode shoe ties iaa arai UMP E EE 7 Reading SCIMUS e crenn iesma aa e eH d a a da rs a os 9 Programming DPS 242344 usce RS Er Ra EPIS aie MERE ES 10 Push Button Control PET sy AAA 11 ii e AAA 11 Issuing Commands 225 24 daria ci aida 11 Reading Stasie 43 desserts cd presiso ties beds coria 11 DOS eee 12 Chapter 13 Reference Setup Parameter Hierarchy vus sow ebecsy rrera ARA 1 Error Messages 254 sinks xa d
80. ction is only enabled when both controllers are activated Controller activation is discussed in Chapter 4 section 1 5 Enabling the Controller When the throttle controller receives an enable request it first reviews an internal list of conditions that must and or must NOT exist in order to enable the controller If all conditions are satisfied the controller is enabled If not an appropriate error message is reported The following conditions must NOT exist when attempting to enable the throttle controller ESTOP Controller Fault Soft Shutdown Reset continuously asserted Controller Operation Dyn Loc V User Manual 9 3 Chapter 11 Throttle Control Pressing the RESET button will attempt to clear out all of these conditions If the root cause s of these conditions is no longer present the reset will succeed and the controller will now accept another enable request If the root cause s persist the reset will not be able to clear out all of these conditions and the controller still cannot be enabled The following digital inputs must be asserted in order to enable the throttle controller If not present an appropriate error message is reported Master Enable apply 24 vdc to pin 16 of the GENERAL PURPOSE I O connector PAUOK apply 24 vdc to pin 24 ofthe THROTTLE CONTROL connector ILK short pin 17 to pin 16 or 35 ofthe THROTTLE CONTROL connector Note The Master Enable input requirement can be over
81. ctuator towards the desired 100 percent position but only until the actuator reaches the existing 100 percent position At this point the actuator stops and the UP button must be repeatedly touched to get the actuator to move past the existing upper limit 7 When the throttle is at the desired 100 percent position touch the ENTER button The position reading is set to 100 percent the UPPER LIMIT annunciator turns off and the ACCEPT LIMIT annunciator turns bright red 8 Touch the ENTER button again to accept the new upper limit setting All annunciators turn off and the actuator returns to the O percent position 11 14 Actuator Dyn Loc V User Manual 7 3 2 7 3 3 Chapter 11 Throttle Control Note At the end of position calibration touch the Save button to permanently save the actuator position settings Note When calibration is complete the ENTER button functions as a jog button Touch and hold the ENTER button to slew the actuator towards the 100 percent position Release the ENTER button and the actuator returns to its original position Note When calibration is complete the SOFT SHUTDOWN button can be used at any time to return the actuator to the 0 percent position if not already there Remote Station Calibration Remote Station calibration is identical to Local calibration described in the previous section except the front panel setup buttons are disabled forcing similar buttons on the Remote Station box
82. cure CALIBRATION parameter to the desired value Set the Secure TUNING parameter to the desired value Set the Secure Mode parameter to On A OD If this is the first time the security feature is being enabled the Powerup Secure Mode parameter must be set to On Note When done touch the Save button on the main setup page to guarantee that all new security settings are saved in non volatile memory Note Be sure to set the Powerup Secure Mode parameter to On to totally secure the Dyn Loc V If not the Dyn Loc V can be put in a non secure mode by simply cycling the power 9 4 Accessing a Secure System Dyn Loc V User Manual 1 0 2 0 Chapter 10 Cell Assistant Overview Cell Assistant is a data acquisition and control software package developed by Dyne Systems Many device drivers are available allowing Cell Assistant to acquire data from and to control many devices such as PLC s gas analyzers fuel systems etc This section describes the Cell Assistant device driver for the Dyn Loc V controller Familiarity with Cell Assistant is assumed throughout this chapter Device Setup Pages As with all Cell Assistant device drivers several Device Setup pages are available to configure the Dyn Loc V and to test all communications with the Dyn Loc V Chapter 10 Cell Assistant 2 1 Controller Pages A diagnostic page exists for the Dyn Loc V as well as an optional throttle controller
83. d gt Motor 4 Quadrant Voir yx Knut hen 7 By Wire Settings as herbas ue dks RAE ri E adaga TES Y Se ads 8 Position Feedback nee otcesivessetatearscediueheeecevesbucesvensesads 9 Setup Parameters Lies Ls ace d AA ADA 9 Position Feedback Sources isses xe Exe dades Edo EGRE EP ER 10 Digital Actuator Encoder Feedback c22 c0snceer ded ibeaidetate a 10 Analog Actuator Feedback cunde d Ede date Cee seed ner RE ES 11 TPS SENSO eiet ke y ax EE nds wad Faas va 11 hol MP isasi poa buar oDe Bey hwo eh GRE Ses deur igss 11 Mechanical Setup usares A DAN es 11 Calibration Page 424 tyes dude RR SECS SR eg E P A ey dde EM as 11 Callbrati n Proc dufe s 22224502679 REOS irainen naa diera 13 Local Mode Calibration is ss 13 Remote Station Calibration or A o Re 13 Manual Cabrones Pads dare 15 LOMA ESA SONS a 16 Actuator Paramelets 2 42239 pata a dE ERE 16 Controller Hatt Wate ses sites dead REPRE RP RRESPDEP ER citar I7 Programmable Analog Outputs 2 p02 os esc E VR Yn RE RR CERE I7 Analog Inpuls 22s exe SaaS exe ead Pages AERE a 17 Connector DUDA AA 17 TES A 17 ANALOGNO 0 diarios a Shed A Ree TSR SARS SOR aah 17 THROTILE CONTROL 22240192993 5595999 ias added dE 17 MA A I7 Pugs erue pix Re T aa sae eR eh raa TH wa Foch ob Tala e itai 18 Controller Operation ca 2 26 ovine hbs 544505048 EAS dorar 18 Mode and Enable Conflict Detection guisa rh REX RTERS GARY Ye TR 18 Enabling the Controller cuestion tai a ERAS 18 Controller Pauls e
84. d Cell Signal O 3 250x differential load cell input EXC Common 16 Load cell excitation Ai EXC O 4 10 volt load cell excitation EXC Common 17 Load cell excitation Ai EXC O 5 10 volt load cell excitation SENSE I 18 Sense line for EXC regulator SENSE I 6 Sense line for EXC regulator n c 19 n c 7 n c 20 n c 8 Shunt CAL Enable Common 21 Pi n c 9 Shunt CAL Enable Common 22 Pi External Shunt CAL Enable O PLC 10 Enable external calibration resistor Shunt CAL Enable Common 23 Pi External Shunt CAL Enable O PLC 11 Enable external calibration resistor n c 24 Shield 12 Torque sensor input shield Ai TS Common 25 Torque sensor common Ai TS Input I 13 10 volt torque sensor input NOTES 1 For 4 wire load cell connections connect pin 5 to pin 6 Also connect pin 17 to pin 18 2 Connectpin3 to pin 13 to measure load cell voltages Dyn Loc V User Manual Connector Summary 13 29 Chapter 13 Reference 4 1 3 ANALOGI O Type DB 15 female VGA Signal Type Pin Description Programmable Analog Output 1 O 1 10 volt output Common 6 Ai Shield 11 Ai Programmable Analog Output 2 O 2 10 volt output n c 7 n c 12 Programmable Analog Output 3 O 3 10 volt output Common 8 Ai Shield 13 Ai Analog Input 1 I 4 10 volt input 15 volts with 5K series resistor 9 See note 1 15 volts with 5K series resistor 14 See n
85. d Threshold 1 0 0 RPM 13 At Speed Threshold 2 0 0 RPM 14 At Speed Deadband 1 0 0 RPM 15 At Speed Deadband 2 0 0 RPM 16 Loss of Speed Feedback Start Delay 1 0 seconds 17 Dyno Error Output Invert Polarity No 18 Powerup Mode Speed 19 Timeout Value Coolant ILK 2 0 seconds 20 Timeout Value PAU ON 2 0 seconds 21 Shaft A B Selection Source Shaft A Always 22 BSTOP Braking Force 100 of ESTOP braking force 23 ECPAU ESTOP Current Limit 100 of ECPAU Current Limit 1 Sec Averaging 10 Transducer Type MAG Pickup 11 Transducer PPR 60 pulses rev 12 Direction Type if Encoder Quadrature Chapter 13 Reference 13 2 Han 13 RPM Input Dynamic Range 14 Speed Scaling 1 0 15 Invert Polarity No 5 000 RPM 16 Digital Noise Filter Non 17 Reference Sourc Torque O Display Resolution 1 1 Display Units LB FT 2 Display Filter 4 Sec Averaging 10 Transducer Type Load Cell 11 Calibration Typ Operator Interface or COMPUTER Zero 1 Sided Span default 12 Torque Sensor Sensitivity 0 1 volts torque unit 13 Load Cell Full Scale Value 14 Load Cell MvV 4 0 15 Load Cell Radius 1 0 16 Setup Force Units LB 17 Setup Length Units FT 18 Torque Calculation None 19 Invert Polarity No 20 Reference Sourc Faults Hard Over speed 50 0 0 Dyno Controller Action ESTOP 1 IGNORE overrides other settings
86. d of the actuator arm approximately 4 inches of linear movement is available Move the attachment point down towards the center or rotation to reduce the linear movement as needed Linear movement can be increased either by moving the attachment point up 1 e away from the center of rotation or by increasing the amount of required actuator rotation if possible In general increasing the amount of required actuator rotation is preferable in fact the actuator calibration will not be accepted if the actuator span is less than approximately 50 degrees Calibration Page Actuator setup is considered a position calibration procedure Chapter 2 section 3 2 describes how to access this calibration page for all installed actuators The position calibration page is shown below Dyn Loc V User Manual Actuator 11 11 Chapter 11 Throttle Control UPPER LOWER ACCEPT FAULT Feedback Counts LIMIT LIMIT LIMIT 240 OB OC 0 46 UP ENTER Direction Which Limit Setup Information Zero D Span 52000 Counts Setup Mode amp Local SOFT D SHUTDOWN O Remote Station O Manual Messages Save Done The position calibration page has the following components Feedback Reading The position feedback reading in the upper left corner provides a high resolution display of the actuator position in percent and in raw feedback units digital encoder counts or analog position volts
87. de is active The front panel will then display the Enter Password dialog requiring the operator to log in before any changes to the current setup can be made 9 Power cycle required A parameter has changed that requires the controller to be to activate change power cycled in order for the change to take effect e g serial port and network settings 10 Tuning parameters Requests to enable a controller are denied if all of the PID tuning notsetforthis mode parameters are set to zero 11 19 UNDEFINED 20 Soft Over speed Issued to inform the operator that a soft over speed has occurred occurred for the specified throttle controller 13 16 Error Codes Dyn Loc V User Manual Chapter 13 Reference Error Code Text Description 21 RTZ timed out Issued to inform the operator that an actuator Return To Zero RTZ operation failed to complete in the required amount of time The actuator may require some slight tuning modifications the actuator may be stuck and or the throttle cable may be sticking In general the actuator should return and settle to the 0 position in approximately 0 2 seconds anything that hinders actuator movement may cause this error during RTZ operations 22 Soft Shutdown Issued to inform the operator that a soft shutdown state has been occurred entered 23 At lower limit During Local or Remote Station actuator setup modes the Switch to Manual DOWN
88. detection A reset is necessary to clear the fault Afterwards if the fault condition persists the fault will be re detected and the configured fault action will occur again at the new fault onset Note De activated controllers will NOT throw any faults Controller deactivation is discussed in Chapter 4 section 1 5 Dynamometer Controller Fault Actions One ofthe following two lists of fault actions is available for each controller fault The first table lists the fault actions available to faults that are allowed to generate an ESTOP this table applies to most controller faults The second table lists faults that are NOT allowed to generate an ESTOP An ESTOP fault action is not allowed for some faults because an ESTOP causes the controller to become enabled and that is not desirable for some fault conditions For example enabling the dyno after a loss of coolant fault occurred could damage the system Fault Actions List with ESTOP Action Included Path Dyn Loc V Faults lt any fault ID Parameter Values Description 0 Dyno Controller ESTOP Select if an ESTOP or BSTOP should occur if Action BSTOP the controller should be turned off or if the Dyno OFF controller should be turned off and then disabled Dyno OFF and Disable i e cannot be turned on again until a reset occurs 1 IGNORE overrides Yes No Use this setting to override selected fault action other settings thus ignoring the specified fault Se
89. disabled the falling edge is ignored TORQUE SPEED Select Rising edge Issue a torque mode request to the dyno controller If the controller is already in torque mode the rising edge is ignored TORQUE SPEED Select Falling edge Issue a speed mode request to the dyno controller If the controller is already in speed mode the falling edge is ignored Note there is no means to report errors when digital commands are issued If a controller fails to enable and or change modes issue a similar request at an Dyn Loc V front panel Since the requested operations are the same the request issued at the front panel should also fail but will also display a helpful error message Dyn Loc V User Manual Digital Control 4 21 Chapter 4 Dynamometer Control As mentioned previously since these digital inputs are edge triggered digital control can be used simultaneously with other control interfaces 1 e host computer control front panel control etc For example a rising edge on the ON OFF Select will enable the dyno controller then while this input is still asserted an operator can disable the controller by pushing the appropriate button on the front panel To re enable the controller digitally the ON OFF Select input must then be de asserted and then re asserted In order to prevent spurious controller enabling and or controller mode changes several safety features have been incorporated into the digital contr
90. drant by wire position and speed configurations as explained in Chapter 11 section 5 4 and Chapter 11 section 5 7 As a complement to this feature the Dyn Loc V dynamometer controller implements special 4 quadrant controller processing as well When either of the 4 quadrant throttle controller modes is enabled the eddy current dynamometer controller will control the absolute value of the speed and torque feedback All displayed readings will still display the correct sign however the PID control loop will control the absolute value of the reading General Controller Concepts Dyn Loc V User Manual 1 9 1 9 1 Chapter 4 Dynamometer Control Note Because an eddy current dynamometer cannot produce sufficient torque at low speeds and ultimately produces no torque at zero speed the control loop essentially loses control as the test system slows down and changes direction This transition can be smoothed somewhat by properly setting the Eddy Current Dropout Speed parameter see section 3 0 to some small speed value Below this speed the control loop integrator will be discharged otherwise the integrator can saturate i e charge to 10 VDC and create unnecessarily large coil currents Dual Shaft Operation Some dynamometer based test systems are configured such that a device to be tested can be mechanically coupled to either shaft of the dyno but not at the same time This is referred to as dual shaft and or
91. e pee Actuator Parameters 0P 7 0 11 70 0 2D 5 0 3 Feedback Filter 20 Hz 4 Ramp Rate non position modes 500 0 per second By Wire Control 0 Command Voltage 100 10 0 volts 1 Command Voltage 0 0 0 volts Pp Dynamometer 0 Dyno Rated Horsepower 0 0 HP 1 Dyno Inertia 0 0 2 Dyno Inertia Units slug ft 3 Eddy Current Dropout Speed 10 0 RPM Calibration Weights 0 Weight Units LB 1 Local Gravity 9 80665 m sec Weights t Weight 1 0 Value 0 0 1 Serial Number 000000001 Dyn Loc V User Manual Setup Parameter Hierarchy 13 13 Chapter 13 Reference 13 14 t Weight 2 0 Value 0 0 1 Serial Number t Weight 3 0 Value 0 0 1 Serial Number t Weight 4 0 Value 0 0 1 Serial Number t Weight 5 0 Value 0 0 1 Serial Number t Weight 6 0 Value 0 0 1 Serial Number t Weight 7 0 Value 0 0 1 Serial Number t Weight 8 0 Value 0 0 1 Serial Number Weight Sets Set Set Set Set Set Set Set JOS 040U0YN RO Setup Parameter Hierarchy Set O YOUR WNE ll 000000002 000000003 000000004 000000005 000000006 000000007 000000008 Dyn Loc V User Manual Chapter 13 Reference 2 0 Error Messages The Dyn Loc V may return errors in response to operator actions these errors are referred to as synchronous errors because they are synchro
92. e ANALOG I O connector of the respective controller see Chapter 13 section 4 1 3 and Chapter 13 section 4 2 2 Each programmable output is a 10 volt output The signal present at each programmable output is selected from a list of available signal sources Note Redundant programmable outputs are allowed For example one two or all three analog outputs can be configured to provide the same output signal if necessary This can greatly simplify wiring if sufficient spare programmable outputs are available Instead of trying to crimp two or three wires into a single pin simply define two or three identical analog outputs and crimp one wire into each pin Dyn Loc V User Manual Controller Hardware 4 11 Chapter 4 Dynamometer Control 4 1 1 Setup Parameters The following setup parameters pertain to each programmable analog output Path Dyn Loc V Dyno Control 1 01 Path WDyn Loc V Throttle Controller Throttle Control 1 01 Programmable Analog Outputs Output N ID Parameter Values Description O Source None Selects the signal source for each source 1 programmable output They are source 2 summarized in the section that follows source N Default selection None 1 Gain Adjustment 1 0 See section 4 1 2 2 Offset Adjustment 0 0 volts See section 4 1 2 Output Scaling Analog output signal sources are based on 0 to 10 volt scaling If the external device or interface that
93. e PESADO sees 6 Membrane Keypad BuUons esa ker me rd ARE eR E RE cas 7 Controller Operation Buttons i225 base RET PR PETRA PRECES ES 7 Contieuration BUM sore been ete REY WE rt Cases de cant 8 Table of Contents Beton e eode ue dus dedu dar deo et de Lou desde 8 JU usa es E ERE rd EE S P T Saar s AAA SETH 12 Calibrate ico esaiex fessbestQbbesc4R E esREANRbescaniceakis 12 Numeric Keypad BINOS cd I EPUM RR E RERO RESP RM 12 Front Panel Operations 25395 syes paus sas SEA Chee Pad Rae TY PADRE e 2 13 Controller Mode Changes ooa duas tease krati a aea RIA RSA dA 13 EMELEC ODIN ss A UH ROS SRI CA CI ERR RYE 14 Lever Wheel Operation sezesexeezzesideb ae di RR HESS 14 Loading Setpoint Values into the Lever Wheels 14 Issuing Lever Wheel Sefpotils sa des dew err rc aa ned 15 Setting Ramp Bales sesdqes sue PETERE ias ar ia Y 15 PALA 63382542 Race Aha Le hea Vade p AGE RE ede PEN Rd 17 Messages cedes dried eon eiae ap UU RIS ERO RR E E dee 18 Chapter 3 Setup Basics Dyn Loc V Setup Parameters 212222222 2302s Vo a morros ener askeei heak 1 Accessing the Dyn Loc V Setup Pace pu poe oe ae aaa ias AGA Gas 1 Setup ree Basics po cketswe seas rn Chess eee GENE Sees eee DRT RA 2 Parameter List Basics 202 iroi icai tets ade needs Gu as Edd dius 3 Setup Tree and Parameter List Navigation aii v pr Res 3 Stylus Navigation 244232 PESO pra Rue re ER EP oad See 3 Keypad NavicalloD estsocidenitoriderdocria ipo i n dna 3 D
94. e PX HER 17 Analog Reference SCaln so sete iAels eds qu RR sidoin ognie sages 18 Speed SCIDDLD S e Sora eed meos actes da edi eee eee de v gd ee M ES 18 Torque Setpoint css dure RR E Eu EE E RE P EE Ee I9 Position Setpolll s2iesipebibsevBbe ees Rs iona esr noa hrer aa 20 Chapter 8 General Purpose I O Card OVEIVICW a ee Ss Ake Be Ae as iia os aa 1 Polly arame isnt cat es a POE Hoe ROS A A IE eda A Ed P Cae es 1 Serial Port Connections 0 0 0 0 ra 3 COMPUTER Connection ese ce co ics RR Ya xp RE Tau Ee eA 3 Setup Pardme ets o lio ovioo4 ossResesbySEOQGedoG P Peerke P Sai 3 DES Connections sus iara e DE EA AR 3 Network Connections 3 NETWORK Connection scarcer bus cuts e rei aroe o eed d Rhe Dra dd 3 Setup PatameterS cosa pus ad x oes aye RAMUS dae aoe aures AM Pas adr as 4 Dyn Loc V User Manual TOC 5 Table of Contents TOC 6 Programmable Digital Outputs esses dans Ch ute e ra tee eror Samy de 4 Setup Parameters serodio massae e lewis eed FEET A 5 Programmable Digital Inputs coossuerieosids tico 7 Setup ParanieleS as siu ei pa a RED o oa 7 ESTOP rm 8 ESTOPTIDUIS 23 5599 pradera teria idiotas Sede OL CES 8 ES passe Inputs sas nda E vt y PRX Es AES TIER URS o 8 ES DOPQOUDUS es pred ree v ure digas bes TP Mx e REPE SO RR Yea a qe pei 8 ROS easRwetbxesPesesgsb weskrqui aera ica 9 Connector SIT ces were URS RENS REESE OM PIER Rd EE 9 424 VDC suas A RARE HANS Ex RJ Ad RARA 9 0C51 005 2 and OCS J cceost ws
95. e button is initially pressed It makes no sense to hold down a button after is has been pressed 3 1 Controller Operation Buttons RESET MASTER COMPUTER When the RESET button is pressed a 0 1 second reset pulse is sent to the Dyn Loc V The onset of the reset pulse will attempt to clear any ESTOP faults and or soft shutdown conditions that may exist The message line on the front panel will be cleared The reset pulse is propagated to all connected PAU s via the Dyno and Throttle Control connectors and to all configured RESET outputs on the GPIO connector Press this button to toggle the controller between Master and Computer modes See Chapter 4 section 1 1 for more information on Master and Computer modes Note Itis rarely necessary to put the controller into Computer mode The controller will automatically switch to Computer mode whenever a controller command is received via the COMPUTER port This button is usually pressed to return the controller to Master mode prior to issuing a controller command from the front panel ON OFF SET Dyn Loc V User Manual Press this button to toggle the Enable Disable state of the controller There are many requirements that must be satisfied before the controller can be enabled Check the message line for errors if the controller fails to enable The enable requirements for the controller are listed in Chapter 4 section 5 1 Press either of the two SET buttons to load setpoint valu
96. e or more fatal hardware errors have been detected A detailed list of the boot errors that were detected is also displayed No controller commands will be accepted until all boot errors have been corrected The Dyn Loc V must be rebooted to clear out this error condition 2 DLS configuration Issued when a parameter is changed Each front panel will refresh has changed the currently displayed page in order for the configuration changes to take effect 3 EEPROM erase Issued after the EEPROM has been erased This is a factory mode completed operation that can only be performed at Dyne Systems 4 Configuration erase Issue after all setup parameters have been erased This is a factory completed mode operation that can only be performed at Dyne Systems 5 Configuration save Sent after the Save button has been pressed in setup mode and all completed configuration data has been successfully saved to non volatile memory Only sent to the front panel that issued the save command 6 Ramp rate has Issued when the ramp rate of any control variable of any installed changed controller has changed Each front panel will refresh the currently displayed ramp rate values if necessary 7 blank line This notification code is never displayed since it is a blank line It is sent to all front panels when the Reset button is pressed in order to clear the message line 8 Password required Issued when an operator attempts to enter setup mode and secure mo
97. ected to Pins 5 6 and or 18 as described in section 3 3 1 Operation of all inputs is described in section 4 2 Outputs 1 thru 8 gt gt Annunciators most likely within the Push Buttons Wire Outputs 1 thru 8 on the DIGITAL CONTROL connector to appropriately labeled 24 VDC annunciators or lamps Then connect a 24 VDC supply from one of the Output Common pins to the remaining terminals on each of the annunciators Operation of all outputs is described in section 4 2 Selecting an Interface Configuration Dyn Loc V User Manual Chapter 12 Digital Control Card 4 0 Operation 4 1 4 1 1 Computer Control Operation The sections that follow describe what the software on the external host computer must do in order to issue commands to and or obtain status information regarding any installed controller Enabling the Interface In order to prevent spurious controller enabling and or controller mode changes several safety features have been incorporated into the Digital Control feature First of all after the Dyn Loc V is powered up the Digital Control feature is completely disabled until the RESET input on the DIGITAL CONTROL connector is asserted This prevents any spurious activity on the inputs from being acknowledged until the Dyn Loc V is reset Resets that occur from other sources e g the GENERAL PURPOSE I O connector Dyn Loc V front panel etc will NOT enable the Digital Control feature thus the external hos
98. ection Using Shaft B Asserted whenever the specified dyno controller is configured for dual shaft operation and is now using shaft B Dual shaft operation is discussed in Chapter 4 section 1 9 Reset Follows the internal reset state of the Dyn Loc V The reset state of the system is the logical OR of reset commands that arrive from any or all of the serial connections as well as the Reset input on the GENERAL PURPOSE I O connector Soft Shutdown Asserted when a soft shutdown condition exists Can only be cleared by a reset DL5 Power Fail ESTOP Follows the state of the PFAIL signal from the DS801 power supply board This signal is not latched Follows the internal ESTOP state of the Dyn Loc V OK to Run no ESTOP and no Fault Asserted when no ESTOP or fault conditions exist All Controllers Disabled Asserted when all active controllers are NOT enabled Throttle Controller Sources These sources are present ONLY if an optional throttle controller is installed Source Description THR Controller is ON Asserted whenever the throttle controller is enabled THR Controller is LOCKED Asserted when the status of the active control loop of the throttle controller is locked Control loop lock status is described in Chapter 4 section 1 4 THR Coolant Enable Asserted whenever the throttle controller is enabled or whenever a soft shutdown condition ex
99. ed ESTOP Bypassing Inputs If any of the previously listed ESTOP input sources is missing and or is not functional the respective source must be permanently or temporarily bypassed as needed Bypassing unconnected ESTOP sources is described in section 10 0 ESTOP Outputs An optically isolated ESTOP output representing the ESTOP state of the controller is available on the GENERAL PURPOSE I O Connector see Chapter 13 section 4 3 4 ESTOP Dyn Loc V User Manual Chapter8 General Purpose I O Card 8 0 Reset Reset commands to the Dyn Loc V can arrive from many sources pressing the RESET button on the Dyn Loc V front panel asserting the Reset input on the GENERAL PURPOSE I O connector issuing a reset command from a host computer etc The duration of the asserted reset from any of the sources may vary however the Dyn Loc V internally enforces a minimum duration for any reset command If any reset is asserted for less than the minimum allowed reset time the reset is internally maintained stretched as needed in order to persist for the minimum reset duration The minimum duration is specified by the following system parameter Path Dyn Loc V System Parameter Values Description Minimum Reset duration 0 25 seconds Valid range is 0 25 to 5 0 seconds 9 0 Connector Summary 9 1 9 3 9 4 9 5 24 VDC Supplies 24 VDC input power to the Dyn Loc V Contact Dyne Systems as various power
100. eed Feedback 1 1 Setup Parameters Every controller has a Speed Control Variable object This object maintains all setup parameters that determine the feedback source scaling and display appearance of the speed reading for the respective controller Chapter 7 Transducers Path Dyn Loc V Control Variables Speed ID Parameter Values Description O Display Resolution 10 Decimal point resolution for speed reading on all 1 displays 0 1 0 01 0 001 Display Units RPM Units for speed reading on all displays 2 Display Filter None Amount of display filtering applied to speed reading 1 Sec Averaging on all displays 2 Sec Averaging 4 Sec Averaging Default speed display filter 1 Sec Averaging 8 Sec Averaging 10 Transducer Type Encoder Encoders and MAG Pickups are wired to different MAG Pickup input pins on the SPEED connector This parameter specifies which speed source is used 11 Transducer PPR 60 Enter the pulses per revolution PPR of the installed encoder or MAG Pickup Any value greater than zero is allowed 12 Direction Type if Quadrature If an encoder is used this parameter selects how Encoder Binary direction information is provided Select Quadrature if the encoder outputs a phase shifted quadrature clock signal select Binary if the encoder outputs a binary direction signal 13 RPM Input Dynamic 100 RPM Specify the operating speed range of the sy
101. em Fault Asserted whenever a controller fault condition exists Controller fault condition is described in Chapter 5 section 3 0 Fault Internal Faults Only Asserted whenever a controller fault condition exists that was caused by any of the internally generated controller faults It will NOT be asserted if a controller fault condition was externally generated only by the occurrence of one or both of the External Input faults Controller is ON Asserted whenever the controller is enabled Controller is LOCKED Asserted when the status of the active control loop of the controller is locked Control loop lock status is described in Chapter 4 section 1 4 Controller in TORQUE Mode Asserted whenever the controller is in torque mode Dyn Loc V User Manual Programmable Digital Outputs 8 5 Chapter8 General Purpose I O Card Source Description Coolant Enable Asserted whenever the controller is enabled or whenever a soft shutdown condition exists Allows coolant to continue flowing after a soft shutdown has occurred PAU OK Replicates the state of the PAU OK input pin of the specified DYNO CONTROL connector see Chapter 13 section 4 1 4 Wrong Direction Asserted whenever the system is spinning in the wrong i e negative speed direction This output is not latched it de asserts as soon at the system stops spinning or spins in the correct i e positive speed dir
102. en follow the Local calibration procedure but move the actuator arm manually were needed Dyn Loc V User Manual Actuator 11 15 Chapter 11 Throttle Control 7 4 Tuning In addition to the outer control loop used by the throttle controller to control speed or torque the throttle controller also has an inner control loop that controls the position of the actuator at all times Inner loop control of all actuator movement needs to be tuned in order to get quick and precise actuator movements even at high slew rates e g 500 percent second 7 4 1 Actuator Parameters The actuator tuning parameters are listed below They are set at the factory and should not be changed Path Dyn Loc V Throttle Controller Actuator Parameters ID Parameter Values Description 0 IP 7 0 Kp constant Negative values not allowed 1 I 70 0 Ki constant Negative values not allowed 2 ID 5 0 Kd constant Negative values not allowed 3 Feedback Filter 0 None Feedback filter cutoff frequency 1 50 Hz Default 3 20Hz 2 30Hz 3 20Hz 4 15 Hz 5 10 Hz 6 7 0 Hz 7 5 0 Hz 8 3 0 Hz 9 2 0 Hz 10 1 5 Hz 11 1 0 Hz 4 Ramp Rate non position modes 500 0 Ramp rate to be used during non position i e speed and torque control modes Units are percent second 11 16 Actuator Dyn Loc V User Manual Chapter 11 Throttle Control 8 0 Controller Hardware 8 1 8 2 8 3 8 3 1 8 3 2 8 3 3 8 4
103. enerates the reference input voltage cannot be configured to produce a 0 to 10 volt reference voltage as defined above the input can be rescaled as described in Chapter 4 section 4 3 2 Note The maximum allowable input voltage is 10 volts Application of larger voltages may permanently damage the controller Reference Sources Dyn Loc V User Manual Chapter7 Transducers 3 3 2 Torque Setpoint When an analog torque reference source is selected a O to 10 volt signal at the respective input provides the torque reference during torque mode operation The scaling of this signal is shown below The scaling depends on the type of torque transducer i e torque sensor or load cell that is currently providing the torque feedback to the controller Torque Sensor Voltage ry yyy Torque os yo q X Sensor Sensitivity When a torque sensor is providing the torque feedback the scaling of the analog torque reference matches the sensitivity volts torque unit from the torque sensor data sheet For example if the installed torque sensor generates 0 1 volts per LB FT the analog reference should also provide 0 1 volts for every LB FT of torque to be commanded Load Cell Torque desired Volt E x 10 0 028 Input Full Scale Torque The Full Scale Torque value of the load cell is specified by the Load Cell Full Scale Value parameter a force value and the Load Cell Radius parameter These parameters are listed in Chapt
104. er 7 section 2 1 Note Ifthe device or interface that generates the reference input voltage cannot be configured to produce a 0 to 10 volt reference voltage as defined above the input can be rescaled as described in Chapter 4 section 4 3 2 Note The maximum allowable input voltage is 10 volts Application of larger voltages may permanently damage the controller Dyn Loc V User Manual Reference Sources 7 19 Chapter 7 Transducers 3 3 3 Position Setpoint When an analog position reference source is selected a 0 to 10 volt signal at the respective input provides the position reference during position mode operation The scaling of this signal is shown below Position Jesired Voltage nput 10 0 For example an 85 analog position setpoint requires an input voltage of 8 5 i e 85 10 volts Note If the device or interface that generates the reference input voltage cannot be configured to produce a 0 to 10 volt reference voltage as defined above the input can be rescaled as described in Chapter 4 section 4 3 2 Note The maximum allowable input voltage is 10 volts Application of larger voltages may permanently damage the controller 7 20 Reference Sources Dyn Loc V User Manual Chapter 8 General Purpose I O Card 1 0 Overview The GPIO card provides general functionality and inter connectivity for integrating the Dyn Loc V into the test cell This card contains a serial port connection to a host compu
105. erarchy Reference 13 11 Chapter 13 Reference 13 12 3 Feedback Filter None 4 FF 0 0 Set 7 0 Description undefined Speed Parameters 0P 0 0 i r 0 0 2D 0 0 3 Feedback Filter None 4 FF 0 0 Torque Parameters 0P 0 0 11 0 0 2D 0 0 3 Feedback Filter None 4 FF 0 0 Set 8 0 Description undefined Speed Parameters P 0 0 I 0 0 D 0 0 Feedback Filter None FF 0 0 SS WIN HO Torque Parameters OP 0 0 LE 0410 2D 0 0 3 Feedback Filter None 4 FF 0 0 Set 9 0 Description undefined Speed Parameters P 0 0 I 0 0 D 0 0 Feedback Filter None FF 0 0 Torque Parameters 0P 0 0 T op 050 2D 0 0 3 Feedback Filter None 4 FF 0 0 H Throttle Control I O Setup Parameter Hierarchy Dyn Loc V User Manual Chapter 13 Reference Programmable Analog Outputs qe Output 1 0 Source None 1 Gain Adjustment 1 0 2 Offset Adjustment 0 0 volts deeem Output 2 0 Source None 1 Gain Adjustment 1 0 2 Offset Adjustment 0 0 volts PR Output 3 0 Source None 1 Gain Adjustment 1 0 2 Offset Adjustment 0 0 volts Analog Inputs fe Input 1 0 Offset Adjustment 0 0 volts 1 Gain Adjustment 1 0 2 Input Filter None y Input 2 0 Offset Adjustment 0 0 volts 1 Gain Adjustment 1 0 2 Input Filter Non
106. erence Source Value Description Operator Interface or COMPUTER Setpoint values are manually entered by an operator or are received default from a Host Computer i e are generated by a software application This is the default setting Analog Input 1 Setpoint reference values are continuously read from the specified Analog Input object of the dyno controller card Analog Input 2 Setpoint reference values are continuously read from the specified THR Analog Input 1 Setpoint reference values are continuously read from the specified Analog Input object of the dyno controller card Analog Input object of the throttle controller card THR Analog Input 2 Setpoint reference values are continuously read from the specified Analog Input object of the throttle controller card Note When any analog reference source is selected the Dyn Loc V front panel indicates that an analog reference source is in use by altering its appearance as described in section 3 2 3 2 Reference Source Indication The Dyn Loc V front panel alters the appearance of the displayed readings in order to provide an indication that the reference source for the displayed variable is NOT the typical digital setpoint commands entered from the front panel The standard appearance of a displayed reading is shown in Chapter 2 section 2 1 The setpoint value is enclosed in parentheses and is located in the lower right corner of the reading
107. es into the respective set of lever wheel switches The loaded setpoint values come from one of two sources from manually entered values at the keypad or from captured control variable readings To manually load a set of lever wheels enter a setpoint value using the keypad buttons and then press the ENTER key To capture the current control variable reading and have this value automatically loaded into the lever wheel switches press the ENTER key while the setpoint entry edit box is empty Use of the SET buttons is further explained in section 4 3 Membrane Keypad Buttons 2 Chapter 2 Operator Interface 3 2 Configuration Buttons 3 2 1 Setup Press this button to gain access to all Dyn Loc V and front panel setup SETUP parameters When pressed the Setup Selection dialog shown below is displayed Touch the appropriate button to gain access to Dyn Loc V or front panel setup parameters All control related parameters are stored in the Dyn Loc V thus you typically want to touch the Dyn Loc V button Setup Selection Front Panel Dyn Loc V Setup Parameters The Dyn Loc V contains hundreds of configurable parameters It is important for the operator to understand the organization of these parameters how to navigate through them to find the parameter of interest and how to change the selected parameter Each of these topics is fully discussed in Chapter 3 Please read this chapter before you attempt to change any parameters
108. escription Common I 2 24 VDC Common Ground 1 24 VDC I 3 24 VDC input Dyn Loc V User Manual Connector Summary 13 35 Chapter 13 Reference 4 3 4 GENERAL PURPOSE I O Type DB 37 female Signal Type Pin Description Programmable Output 1 O PLC 1 Programmable Output 2 O PLC 20 Programmable Output 3 O PLC 2 Common 21 Pi Programmable Output 4 O PLC 3 Programmable Output 5 O PLC 22 Programmable Output 6 O PLC 4 Common 23 Pi Common 5 Pi ESTOP O PLC 24 Programmable Output 7 O PLC 6 Common 25 Pi Programmable Output 8 O PLC 7 Programmable Output 9 O PLC 26 Programmable Output 10 O PLC 8 Programmable Output 11 O PLC 27 Common 9 Pi Programmable Output 12 O PLC 28 Programmable Output 13 O PLC 10 Programmable Output 14 O PLC 29 Programmable Output 15 O PLC 1 Common 30 Pi Common 12 Pi Programmable Input 1 I PLC 31 Programmable Input 2 I PLC 13 Programmable Input 3 I PLC 32 Programmable Input 4 I PLC 14 Programmable Input 5 I PLC 33 Power Common 15 Pi Power Common 34 Pi Master Enable I PLC 16 Reset I PLC 35 External reset input ESTOP I PLC 17 External ESTOP command input 24 volt O 36 24 volt O 18 24 volt O 37 24 volt O 19 13 36 Connector Summary Dyn Loc V User Manual Chapter 13 Reference 4 4 Digital Control Back Panel The pin descriptions of each connector on the back of the
109. ess the other controller is enabled and controlling speed Instead of disabling mode conflict detection one ofthe controllers can simply be de activated The Dyn Loc V will then behave as a single controller system and allow one controller to run in torque mode An actuator power amplifier unit PAU or other external device may be temporarily in operative resulting in controller faults that prevent the working controller from functioning De activating the faulty controller allows the other controller to operate in single controller mode De activating a controller has the following effects Ade activated controller cannot be enabled Ade activated controller will NOT throw any controller faults The front panel display of a de activated controller will be disabled fade activated controller is paired with another controller for mode and enable conflict detection the mode and enable conflict rules no longer apply to the other controller A controller is activated and de activated by changing the controller Status property as listed in section 2 0 ESTOP Action At the onset of an ESTOP condition a dyno controller will make a reasonable attempt to bring the test system to a quick stop If the controller is already enabled and running when the ESTOP occurs the controller will switch to an ESTOP state If the controller is disabled at the onset of an ESTOP the dyno controller will enable itself and enter the ESTOP state
110. et is selected by changing the Active Parameter Set Number as listed in Chapter 4 section 2 0 In most installations only a single parameter set Set 0 is used 3 0 Tuning Page Display Controller tuning is performed using a full featured high resolution graphical tuning page All tuning parameters can be quickly adjusted while observing changes to the system response on the graphical display The tuning page is described in the next section Dyn Loc V User Manual Tuning Page Display 6 3 Chapter6 Tuning 3 1 Graphical Tuning Page Period 5 seconds Enable Setpoint Cycling 0 AA AS IS ESTOP FAULT A SE E m E I Messages The graphical tuning page is displayed above This page is displayed when the TUNE button on the front panel is pressed It consists ofa 100 Hz graphical trace of the reference RED and feedback BLUE waveforms The controller mode to be tuned must be selected prior to pressing the TUNE button on the front panel Configuring the Waveform The time scale of the waveform is configured by touching the Period button A pop up dialog is displayed providing three time scale selections 5 10 or 20 seconds Each X axis tick mark represents 1 second A vertical grid line appears at 5 second intervals The Y axis presents two labels that define the vertical range The vertical range is always divided into five intervals 20 each with an additional 20 overshoot and 20 undersh
111. ever if Buyer wants warranty work to be performed onsite and Dyne Systems deems it feasible then Buyer will be responsible for travel hours and travel transportation costs Dyne Systems is not liable for costs incurred such as loss of work time or production time or for loss of profits or other damages including but not limited to consequential damage THE FOREGOING WARRANTIES ARE EXCLUSIVE AND ARE GIVEN AND ACCEPTED IN LIEU OF ANY AND ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING WITHOUT LIMITATION THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE THE REMEDIES OF BUYER FOR ANY BREACH OF WARRANTY SHALL BE LIMITED TO THOSE PROVIDED HEREIN AND FOR DELAY OR NON DELIVERY WHICH IS NOT EXCUSABLE TO THE PURCHASE PRICE OF THE GOODS IN RESPECT OF WHICH THE DELAY OR NON DELIVERY IS CLAIMED TO THE EXCLUSION OF ANY AND ALL OTHER REMEDIES IN NO EVENTSHALL DYNE SYSTEMS BE LIABLE FOR SPECIAL INDIRECT OR CONSEQUENTIAL DAMAGES INCLUDING WITHOUT LIMITATION LOSS OF USE OR PROFITS NO AGREEMENT VARYING OR EXTENDING THE FOREGOING WARRANTIES REMEDIES OR THIS LIMITATION WILL BE BINDING UPON DYNE SYSTEMS UNLESS IN WRITING SIGNED BY ADULY AUTHORIZED OFFICER OF DYNE SYSTEMS DYNE SYSTEMS LIABILITY FOR FAILURE TO COMPLY WITH ANY WARRANTY OR REPRESENTATION HEREUNDER SHALL BE LIMITED TO THE VALUE OF THE GOODS SOLD HEREUNDER Excluding equipment made for integrated systems supplied or made by Dyne Systems Dyne Systems makes no w
112. exists The soft shutdown condition must be cleared before the enable request will be accepted Dyn Loc V User Manual Error Codes 13 19 Chapter 13 Reference Error Code Text Description 51 Setpoint rejected Position setpoint values less than 0 or greater than the 100 are 0 to 100 not allowed Ifa larger range of actuator movement is required allowed the 0 and or 100 actuator positions should be redefined by recalibrating the actuator 52 Negative speed Ifthe speed control variable is properly configured the normal setpoints are not direction of rotation should result in positive displayed speed allowed values thus negative speed values are not allowed 53 Secure mode Setup calibration and tuning may not be allowed when the enabled function Dyn Loc V is in secure mode Contact the person responsible for not allowed security A password is required to take the Dyn Loc V out of secure mode 54 56 UNDEFINED 57 Cell Assistantis A Cell Assistant TestPlan has attempted to change the state of a NOT the selection Dyn Loc V feature but the selection source for this feature is source NOT configured to allow Cell Assistant to make the change For example the dynamometer shaft selection Shaft A or Shaft B can each be controlled by a running Cell Assistant TestPlan however the selection source for this item must be set to allow Cell Assistant to make t
113. face Connection to the Dyn Loc V Two straight through cables are required to connect the optional throttle controller enclosure to the Dyn Loc V main unit Each cable is included with the purchase of the throttle controller One 9 conductor cable with a 9 pin male DSUB connector and a 9 pin female DSUB connector at opposite ends One37 conductor cable with a 37 pin male DSUB connector and a 37 pin female DSUB connector at opposite ends Chapter 11 Throttle Control 3 0 Operator Interface The operator interface for an optional throttle controller is essentially identical to the operator interface for the Dyn Loc V dynamometer controller as described in Chapter 2 however there are a few important differences that will be described in this section The main front panel screen for an enabled throttle controller is shown below The first noticeable difference is the background color it is a pale blue vs light gray for the dynamometer controller main front panel This is done merely to provide additional visual feedback to an operator to help them differentiate the front panel that is managing dynamometer control from the front panel that is managing throttle control The second difference pertains to the arrangement of the readings Whereas the Dyn Loc V main front panel displays Speed Torque and Power readings top to bottom the throttle controller front panel displays Speed Torque and Position readings top to bo
114. frequency 1 50Hz 2 30Hz Default O None 3 20 Hz 4 15 Hz 5 10Hz 6 7 0Hz 7 5 0 Hz 8 3 0 Hz 9 2 0 Hz 10 1 5 Hz 11 1 0 Hz 12 0 5 Hz 13 0 25 Hz 4 FF 0 0 Feed forward control element This parameter is described in section 5 0 If needed it is computed and set at configuration time it can not be tuned The controller maintains a separate set of tuning parameters for each controller mode of operation For example each dyno controller Parameter Set consists of a set of tuning parameters for controlling speed and another set of tuning parameters for controller torque Similarly a throttle controller Parameter Set has a separate set of tuning parameters for controlling speed and another set for controlling torque Clearly each controller mode e g speed can be optimally tuned without affecting the tuning of the other controller mode e g torque Tuning Parameters Dyn Loc V User Manual Chapter6 Tuning 2 0 Parameter Sets The Dyn Loc V maintains 10 unique Parameter Sets as described previously Each parameter set can be given a descriptive name as shown below The Description property can be used to uniquely identify parameter sets used for various engines dynamometers or other devices to be tested Path Dyn Loc V Parameters Sets Set NN ID Parameter Values Description O Description lt undefined gt Note The active parameter s
115. fthe than firmware program that is stored in non volatile memory This error is most likely to occur if someone attempts to upload a configuration file created using the latest version of Dyn Loc V software into a Dyn Loc V that contains older software This is not allowed The Dyn Loc V should be returned to Dyne Systems for a software upgrade 174 EEPROM version The version number of the Dyn Loc V parameters stored in newer than EEROM is newer than the version number ofthe program that is firmware stored in non volatile memory This error is most likely to occur if someone installs a new GPIO card 1 e DS605 board that was initialized using the latest version of Dyn Loc V software into a Dyn Loc V that contains older software This is not allowed The Dyn Loc V should be returned to Dyne Systems for a software upgrade 175 Nota Dyn Loc V Using one of several configuration management tools an operator configuration file attempted to upload a configuration file into the Dyn Loc V that was NOT created and extracted from a Dyn Loc V 176 Nota Dyn Loc V During controller power up the format of the onboard EEPROM formatted was determined to be invalid It will be automatically reformatted EEPROM and loaded with default values 177 179 UNDEFINED Hardware Errors 180 199 These errors are caused by defective or failing hardware Error Code Text Description 180 182 UNDEFINED 183 EEPROM is The contents o
116. fthe EEPROM are invalid The Dyn Loc V will damaged automatically try to erase and re initialize the EEPROM AII master ramp rate values for all controllers and the currently selected parameter set for all controllers will be reset to factory default values If the problem persists the Dyn Loc V should be returned to Dyne Systems for repair 184 EEPROM This message is sent as a reminder that the contents of the contents have been initialized EEPROM have been initialized All master ramp rate values for all controllers and the currently selected parameter set for all controllers have been reset to factory default values and need to be re entered Dyn Loc V User Manual Error Codes 13 25 Chapter 13 Reference Error Code Text Description 185 189 UNDEFINED 190 File open error Unable to locate the configuration data file in the flash device The device may be damaged Contact Dyne Systems 191 File write error A write error occurred while saving configuration data to the flash device Press the save button again to see if the write failure is intermittent If the problem persists the Dyn Loc V should be returned to Dyne Systems for repair 192 File read error A read error occurred while accessing configuration data in the flash device Cycle power to the Dyn Loc V to see if the read failure is intermittent If the problem persists the Dyn Loc V should be returned to Dyne Systems for repair 1
117. g in external relative to the load cell precision resistors to unbalance the internal resistor bridge network in the load cell Note The external load cell shunt calibration resistors typically reside on the Dyn Loc V controller boards If so no additional wiring is required Hardware Setup Shunt calibration requires a precision resistor that is used to electrically unbalance the resistor bridge network in a load cell The location and value of this resistor is determined by JP2 This jumper exists on the dyno controller board i e the DS603 board JP2 Position Shunt Calibration Resistor 1 2 Fixed 60 0K precision resistor internal to controller 2 3 Manufacturer supplied precision resistor internal to controller Out External resistor typically internal to the load cell Fixed Value Internal Shunt Calibration Resistor When JP2 is jumpered in the 1 2 position a fixed 60 0K resistor is used as the shunt calibration resistor This resistor resides on the dyno or throttle controller board This resistor value is commonly specified in many factory calibration data sheets Dyn Loc V User Manual Torque Feedback 7 11 Chapter 7 Transducers 7 12 Manufacturer Supplied Internal Shunt Calibration Resistor As explained in section 2 5 shunt calibration is mainly used to check the span and if necessary re span to correct for small amounts of gain drift Some load cells on the other hand are precisely calibra
118. g the actuator position and hence the position ofthe engine throttle This configuration requires the Control Output Type setup parameter to be set to Actuator gt Engine This configuration requires a Dyne Systems actuator and THR PAU The THR PAU is designed to interface directly into the THROTTLE CONTROL connector with no additional external circuitry Position Cmd gt ECM In this configuration the position reference normally presented to the actuator position inner control loop is now wired directly to an external throttle position controller 1 e the ECM viaa programmable analog output The following parameter settings are required to properly configure a throttle controller for by wire position control The Control Output Type parameter must be set to Position Cmd gt ECM One throttle controller programmable analog output see section 8 1 must be configured with a Source set to Command Voltage position This analog output is externally wired to the ECM The Command Voltage 0 and Command Voltage 100 parameters see section 5 8 must be set based on the input specifications ofthe ECM Note Programmable analog outputs are low power voltage outputs with limited current sourcing capability thus the external position control device MUST provide its own power amplifier unit as needed Note The position control variable should be configured to get its position feed
119. ghts Dyn Loc V User Manual Dyn Loc V Setup Parameters 3 9 Chapter3 Setup Basics 1 9 Expanded Top Structure of the Setup Tree The following figure shows the top structure ofthe setup tree with each folder expanded by one additional level EI Dyn Loc V 6 23 Control Variables 63 23 Faults 6 23 Parameter Sets EI Dyno Control 1 0 27 General Purpose 140 73 Programmable Digital Outputs BH Programmable Digital Inputs System 23 Security 239 Hardware 239 Computer Port 0 03 Network Port 5 23 Throttle Controller fq Position EI Faults 73 Parameter Sets 0 23 Throttle Control 140 23 Actuator Parameters 23 By Wire Control 13 Dynamometer 5 44 Calibration Weights 73 Weights La Weight Sets This figure provides a better look at how the Dyn Loc V parameters are organized All ofthese subfolders and the parameters contained in them are discussed elsewhere in the appropriate sections of this manual A comprehensive list of all parameters their organization and their factory default values is listed in Chapter 13 section 1 0 3 10 Dyn Loc V Setup Parameters Dyn Loc V User Manual 1 0 1 1 Chapter 4 Dynamometer Control General Controller Concepts Master and Computer Modes At any given time the controller will only accept control commands e g setpoints on off commands ramp rates etc from one type of external source When in Master mode the controller will only a
120. gle ended Encoder Setup Chapter 7 section 1 3 1 Dyn Loc V User Manual Controller Hardware 11 17 Chapter 11 Throttle Control 8 5 Fuses F1 Install a 1A fast acting fuse BUSSMAN GMA 1A This fuse limits the total current that the PLC outputs on the THROTTLE CONTROL connector can draw from the 24 vdc supply which is input on pins 6 and or 25 of the same connector 9 0 Controller Operation 9 1 9 2 11 18 Mode and Enable Conflict Detection When an optional throttle controller is installed the Dyn Loc V applies additional reasonableness checks to every mode change request and every enable and disable request These checks improve the overall safety of the system by preventing an operator from accidentally commanding run away conditions The following rules are enforced Acontroller is NOT allowed to start 1 e be enabled in torque or an equivalent mode unless the other controller is enabled and controlling speed Acontroller is NOT allowed to change to torque or an equivalent mode unless the other controller is enabled and is currently controlling speed or is enabled and can be switched to speed mode fanenabled controller is disabled leaving the other controller enabled and controlling torque or an equivalent mode the other controller will also be disabled If these rules cannot be satisfied the mode change or enable request will be rejected Note Mode and enable conflict dete
121. hapter 13 section 4 1 3 Throttle 1 TPS 1 Chapter 13 section 4 2 1 Throttle 2 THROTTLE CONTROL 8 Chapter 13 section 4 2 3 4 3 2 Input Scaling Analog input functions are based on 0 to 10 volt input scaling If the device or interface that produces these input voltages cannot provide the required scaling the input scaling can be corrected in the Dyn Loc V The signal processing that occurs for each analog input is shown below Voltage Input pl Input B xM B Offset Adjustment M Gain Adjustment L Input Filter Voltage Input Adjusted Each analog input voltage is offset adjusted gain adjusted and filtered in this exact order Each of these parameters is listed below Section 4 3 3 For example if the available input voltage range is only 2 to 7 volts set the Offset Adjustment parameter 2 0 volts and set the Gain Adjustment parameter 2 0 These values will properly correct the input voltage as follows Offset Input Adjustment Gain Adjustment Input Voltage Voltage 2 0 x 2 0 Adjusted 2 0 0 0 7 5 10 10 4 3 3 Setup Parameters The following setup parameters pertain to each analog input Dyn Loc V User Manual Controller Hardware 4 15 Chapter 4 Dynamometer Control 4 4 4 4 1 4 4 2 4 4 3 4 4 4 4 16 Path WDyn Loc V Dyno Control I O Path WDyn Loc V Throttle Controller
122. hat section The DYNO CONTROL connector is shown in Chapter 13 section 4 1 4 Analog Inputs Each installed controller card provides two analog inputs These inputs are used as follows by the Dyn Loc V Any control variable e g speed torque position etc can be configured to use an analog setpoint reference signal instead of the standard setpoint commands Analog reference sources are explained in Chapter 7 section 3 0 The remainder of this section describes the physical locations of these inputs as well as some general setup features of each analog input Input Locations Each controller provides two analog inputs The physical location of where the input voltage should be applied is listed in the following table Note that the dyno controller uses two spare analog inputs available on the ANALOG I O connector The throttle controller on the other hand does not have any spare analog inputs instead the inputs reserved for a Throttle Position Sensor and an Analog Controller Hardware Dyn Loc V User Manual Chapter 4 Dynamometer Control Actuator Position signal are used to provide the actual input to the analog input objects Clearly these throttle controller inputs are only available as analog input sources if they are not being used for their originally designed purpose Controller Input Connector Pin Connector Information Dyno 1 ANALOG I O 4 Chapter 13 section 4 1 3 Dyno 2 ANALOG I O 5 C
123. he ENTER button In this case the controller will perform a bumpless transfer as part of the normal enable procedure and then immediately take the entered setpoint as the first entered setpoint Note The units of the entered setpoint are the same units used in the reading for the active controller mode For example if speed is displayed in RPM the units of all entered speed setpoints is RPM Note A special case exists when entering setpoints for a throttle controller in position mode Pressing ENTER with an empty setpoint edit box causes a 0 throttle position setpoint value to be sent to the Dyn Loc V Lever Wheel Operation A set of virtual lever switches is shown in section 2 2 The two main aspects of lever wheel operation are 1 loading values into the lever wheels and 2 issuing setpoints from the previously loaded lever wheels Loading Setpoint Values into the Lever Wheels The three methods of loading setpoint values into a set of virtual lever wheel switches are summarized below Front Panel Operations Dyn Loc V User Manual Chapter 2 Operator Interface Method Description Manual Entry Either set of virtual lever wheel switches can be manually loaded by entering a setpoint value using the number keypad and then pressing the respective SET button The setpoint entry edit box will clear and the entered value will be loaded into the respective set of switches Feedback Capture The current reading of t
124. he control variable can be loaded into either set of virtual lever wheel switches by pressing the respective SET button while the setpoint edit box is empty In addition the controller must be enabled Touchscreen Lever wheel values can be entered by touching the upper and lower portions of each digit to scroll the respective digit value up or down Note that each set of lever wheel switches function similar to an automobile odometer i e digit rollovers will affect adjacent digits This method is useful for making small adjustments to an existing setpoint The previously described methods are generally more efficient when entering a completely new setpoint 4 3 2 Issuing Lever Wheel Setpoints The currently loaded setpoint value in any set of virtual lever wheel switches is issued to the enabled controller when the adjacent setpoint send button is touched The setpoint send button is the red touchscreen button immediately to the left of each set of lever wheel switches When touched the button momentarily turns bright red indicating the setpoint has been issued Continuous setpoint operation is possible by pressing and holding the setpoint send button for approximately 2 seconds If touched for the required amount of time the setpoint send button will turn bright yellow to signify continuous setpoint operation The controller is now locked onto the lever wheels The controller will follow the lever w
125. he operation of each input is explained in more detail in section 4 2 Inputs Pin Function Input 1 1 DL5 SPEED mode command Input 2 14 THR SPEED mode command Input 3 2 DL5 TORQUE mode command Input 4 15 THR TORQUE mode command Input 5 3 DL5 ON OFF toggle command Input 6 16 THR POSITION mode command Input 7 4 THR ON OFF toggle command Input 8 17 notused The outputs ofthis Interface configuration continuously output the ON OFF and controller mode status of the two controllers Details regarding the operation of each output is explained in more detail in section 4 2 Outputs Pin Function Output 1 20 THR Is in SPEED mode status Output 2 8 DLS Is in SPEED mode status Output 3 21 THR Isin TORQUE mode status Output 4 9 DLS Is in TORQUE mode status Output 5 22 THR Isin POSITION mode status Output 6 10 DLS Is ON status Output 7 23 lt notused gt Output 8 11 THR Is ON status Note The previous tables only list the functions of the Input and Output bits All pins on the DIGITAL CONTROL connector are shown in Chapter 13 section 4 4 1 12 4 Selecting an Interface Configuration Dyn Loc V User Manual 3 3 1 3 3 2 Chapter 12 Digital Control Card Note The Push Button Control configuration can be used if desired for control by a remote host computer however the Computer Control configuration is a better choice
126. he parameter list can be manipulated just as a computer mouse is used to manipulate standard Windows M controls In most cases a stylus is not available and or is not practical due to the small size of the display objects in this case membrane keys are used to navigate the parameter list Each navigation method is described below Stylus Navigation Setup tree folders can be expanded and collapsed by touching the boxes to the left of each folder Of course folders with no sub folders do not have a box next to them Parameter list items are selected by touching the parameter ID field of the appropriate parameter Double click the parameter ID field to modify the current value Keypad Navigation Complete navigation of the setup tree and selection and editing of parameter values can be accomplished without a pointing device 1 e a stylus Keypad and touch screen keys provide the same functionality Selecting a Folder When the cursor is on the setup tree the following keypad keys are used to navigate through the entire setup tree Moves the cursor to the previous folder All parameters if any in this folder are displayed in the parameter list Moves the cursor to the next folder All parameters 1f any in this folder are displayed in the parameter list Expands the selected folder Collapses the selected folder Dyn Loc V User Manual Dyn Loc V Setup Parameters 3 3 Chapter3 Setup Basics owe Collapses the enti
127. heel values as they are changed Pressing the send button again and or pressing any other button cancels continuous setpoint operation 4 4 Setting Ramp Rates The Up and Down ramp rates of the active control mode can be changed at any time by touching the Ramp Rate button When touched the Ramp Rate dialog shown below is displayed Ramp Rate Speed Dyn Loc V User Manual Front Panel Operations 2 15 Chapter 2 Operator Interface Enter a new ramp rate value using the numeric keypad Use the Left arrow and CANCEL keys to correct mistakes in the usual manner When ready touch the Up Down or Both buttons to change the Up and or Down ramp rates as needed Touch the Cancel button to dismiss the dialog The units of the entered ramp rate values are the same units used in the reading for the active controller mode For example if speed is displayed in RPM the units of all entered speed ramp rates is RPM second Ramp rates are discussed in greater detail in Chapter 4 section 1 2 Note Ramp rate changes take affect immediately even if another setpoint ramp is currently in progress 2 16 Front Panel Operations Dyn Loc V User Manual Chapter 2 Operator Interface 4 5 Fault List A pop up dialog containing a list of all active faults is displayed by touching the FAULT indicator This dialog is shown below When the FAULT indicator turns bright red the operator typically displays the fault list in order to determine the exact ca
128. hese changes 58 59 UNDEFINED 60 Controller is A fault occurred which specified a main fault action of Dyno disabled OFF and Disable The controller is now disabled and cannot be turned on A reset must occur to clear the disable condition 61 Invalid controller A Cell Assistant TestPlan attempted to override the default Mode pairing selection Conflict Controller Pairing setting but it issued an invalid value selection code 62 BSTOP occurred The dyno controller cannot be enabled after a BSTOP has occurred Press RESET and then try again to enable the dyno controller 63 BSTOP in Mode changes are rejected while the dyno controller is executing progress a BSTOP request Wait for the BSTOP to complete and try again 64 65 UNDEFINED 66 Restricted to When a throttle controller is configured for by wire speed speed mode of control no other control modes e g torque or position are operation allowed similarly when a dyno controller is configured to output a speed command voltage to an external AC or DC drive unit the dyno controller is restricted to speed mode of operation 67 Reset is asserted Requests to enable a controller are denied when the Reset input pin 35 on the GENERAL PURPOSE I O connector is permanently asserted Since the Reset input is edge triggered it should always be de asserted immediately after is has been asserted 68 Setpoint exceeds Speed setpoints are rejected if the value exceeds the c
129. i 24 volt supply I 12 1 of 3 pins At least one must supply power Supply Common 25 Pi 24 volt supply I 13 1 of 3 pins At least one must supply power Dyn Loc V User Manual Connector Summary 13 31 Chapter 13 Reference 4 2 Throttle Controller Back Panel The pin descriptions of each connector on the back of the throttle controller back panel board DS604 board are described in the sections that follow 4 2 1 TPS Type DB 9 male Signal Type Pin Description Vin I 1 10 volt Throttle Position Sensor input Signal Common Ai Shield 2 Input signal shield Ai n c n c 3 n c n c 4 Power Common Ai 10 volts O 5 Excitation for Throttle Position Sensor 13 32 Connector Summary Dyn Loc V User Manual Chapter 13 Reference 4 2 2 ANALOG I O Type DB 15 female VGA Signal Type Pin Description Programmable Analog Output 1 O 1 10 volt output Common 6 Ai Shield 1 Ai Programmable Analog Output 2 O 2 10 volt output n c 7 n c 12 Programmable Analog Output 3 O 3 10 volt output Common 8 Ai Shield 13 Ai n c 4 15 volts with 5K series resistor 9 See note 1 15 volts with 5K series resistor 14 See note 1 n c 5 Common 10 Ai Shield 15 Ai NOTES 1 Connecta 10K to 25K potentiometer to Common to create a unipolar adjustable voltage that can be used to drive an analog input Due to
130. ion 6 3 2 3 EPLD Version Slot 4 DS605 board See section 6 3 2 CPU Type To date several types of main CPU boards have been used in the Dyn Loc V The CPU type determines the software update method and the format of the required data file whenever the Dyn Loc V firmware requires upgrading usually in the field This parameter simplifies the determination of the CPU type i e the Dyn Loc V does not need to be removed and or opened Dyn Loc V User Manual Version Tracking 13 39 Chapter 13 Reference 6 3 2 Electronically Programmable Logic Devices The hardware circuitry for each controller and the GPIO board contain several Electronically Programmable Logic Devices EPLD s The hardware version of these devices is located in the Hardware folder shown previously in section 6 3 If the specified board does not exist the version number will display Not installed Earlier versions of the circuit boards did not contain version information in this case the version number will display 2222 Finally if the circuit board is installed and the EPLD does contain version information the version number i e an integer number will be displayed 13 40 Version Tracking Dyn Loc V User Manual Chapter 13 7 0 Constants and Conversions The following constants and conversion factors are used in the Dyn Loc V software 7 1 Constants Value Units Description 9 80665
131. iption 0 Display Resolution 10 Decimal point resolution for 1 torque reading on all 0 1 connected displays 0 01 0 001 1 Display Units LB FT Units for torque reading on LB IN all connected displays OZ IN NM 2 Display Filter None Amount of display filtering 1 Sec Averaging applied to torque reading on 2 Sec Averaging all displays 4 Sec Averaging 8 Sec Averaging Default torque display filter 4 Sec Averaging 10 Transducer Type Load Cell Selects the type of torque Torque Sensor transducer that is used 11 Calibration Type Zero 1 Sided Span Zero 2 Sided Span Zero Multi point Span Selects if one sided or two sided span calibration is to be applied to the torque signal If two sided calibration is selected the system must be capable of being spanned in both the positive and negative torque directions Multi point span calibration is described in a later section 12 Torque Sensor Sensitivity 0 1 Specify output sensitivity of Torque Sensor Units are Volts torque units where the torque units is specified by the Setup Force Units and Setup Length Units parameters Value must be greater than zero Dyn Loc V User Manual Torque Feedback 7 5 Chapter 7 Transducers Dyno Reaction TQ gt In Line Shaft TQ ID Parameter Values Description 13 Load Cell Full Scale 50 0 Rated full scale force value Value from load cell data sheet Units a
132. is connected to these output voltages requires different scaling the output scaling can be corrected in the Dyn Loc V The signal processing that occurs for each analog output is shown below Voltage Voltage Output OutputxM B Output from Source B Offset Adjustment at connector M Gain Adjustment Each analog output voltage is gain adjusted and then offset adjusted in this exact order Each of the adjusting parameters is listed above Section 4 1 1 Signal Sources The tables that follow list all programmable analog output signal sources Speed Source Description Analog RPM reading from the speed transducer Scaling is as follows Voltage RPM reading x 10 0 RPM Input Dynamic Range The RPM Input Dynamic Range setup parameter is listed in Chapter 7 section 1 1 4 12 Controller Hardware Dyn Loc V User Manual Chapter 4 Dynamometer Control Source Description Torque Analog torque reading from the torque transducer Scaling is as follows Torque Sensors Voltage Torque Sensor output voltage The units volt scaling is obtained from the torque sensor data sheet Load Cells Voltage Load Cell output voltage x 250 x 4 0 Load Cell MvV This equation ensures a 10 volt output when a full scale torque value is present The units volt scaling full scale torque value 10 0 where the full scale torque value is specified by the Load Cell
133. is reset Dyn Loc V User Manual Operation 12 7 Chapter 12 Digital Control Card Two commands are issued to the controller one Enable Disable command and one controller mode command whenever the external host software creates a rising edge on the ACTIVATE input i e asserts 24 VDC It is imperative the controller select bits i e CS1 CS0 the mode select bits i e MD1 MDO and the Enable Disable select bit i e ENABLE are all properly set before asserting the ACTIVATE signal The ESTOP and RESET inputs are level sensitive inputs and are continuously active i e they function as described regardless of the state of the ACTIVATE input The following tables lists all values for the controller select and mode select bits Controller Select Bits Mode Select Bits CS1 CS0 Controller MD1 MDO Dyno Throttle 0 0 Invalid selection 0 0 Speed Speed 0 24 vdc Dyno 0 24 vde Torque Torque 24 vdc 0 Throttle 24 vdc 0 24 vde 24 vdc Invalid selection 24 vde 24vdc Note Ifthe Controller Select bits are invalid or the selected controller does not exist the ACTIVATE command is ignored Note Even during periods when no commands are issued the controller select bits are still used to select a controller for outputting the controller status See section 4 1 3 for more information 12 8 Operation Dyn Loc V User Manual 4 1 3 Reading Status Chapter
134. ists Allows coolant to continue flowing after a soft shutdown has occurred THR Is Commanding Negative Speed Asserted whenever the throttle controller is commanding a negative by wire speed command Used with motor controllers that require a unipolar speed command along with a sign bit instead of a bipolar speed command voltage See Chapter 11 section 5 7 for additional information regarding by wire speed control and the need for this output bit 8 6 Programmable Digital Outputs Dyn Loc V User Manual Chapter8 General Purpose I O Card 6 0 Programmable Digital Inputs The GENERAL PURPOSE I O connector provides 5 programmable PLC compatible digital inputs The function of each input is established by picking a function from a list of available digital input control functions Note Most programmable inputs are level sensitive exceptions are noted below The selected input function will be continuously attempted until the input is de asserted Note Redundant programmable inputs are allowed however the results may be confusing For safe and predictable operation of the Dyn Loc V each programmable input function should only be used once 6 1 Setup Parameters The following setup parameters pertain to each programmable input Path WDyn Loc V General Purpose I O Programmable Digital Inputs Input NN ID Parameter Values Description 0 Function None Selects the input function of each progra
135. l digital inputs including ESTOP and RESET are ignored 12 2 Selecting an Interface Configuration Dyn Loc V User Manual 3 2 3 2 1 Chapter 12 Digital Control Card Interface Configuration Types Computer Control This Interface Type is the more generic and more useful of the two selections The function of all inputs bits are listed below Controller commands are issued on the rising edge of the ACTIVATE input signal Prior to asserting the ACTIVATE signal the Controller select bits CS1 CSO the Mode command bits MD1 MDO and the ENABLE command bit must be set as needed Two level sensitive inputs ESTOP and RESET are also provided resulting in a generic single cable connection to a remote host computer Unlike the Push Button Control configuration section 3 2 2 this configuration provides control of all installed controllers dyno and throttle Details regarding the operation of each input is explained in more detail in section 4 1 Inputs Pin Function Input 1 1 Controller select bit O CSO Input 2 14 Controller select bit 1 CS1 Input 3 2 Mode command bit O MDO Input 4 15 Mode command bit 1 MD1 Input 5 3 ENABLE command Input 6 16 ACTIVATE sends commands on rising edge Input 7 4 ESTOP Input 8 17 RESET The outputs of this Interface configuration continuously output several bits of system information i e OK to RUN RESET and ESTOPPED status as
136. ler is controlling an actuator these values can be automatically set during actuator setup Reference Source All selections are listed in Chapter 7 section 3 0 Position setpoints typically are entered by an operator at the front panel however other position reference sources are available Alternate reference sources and the setting of this parameter are described in Chapter 7 section 3 0 6 2 6 2 1 11 10 Position Feedback Sources Several types of position feedback are supported by the throttle controller Each type is discussed below The value of the Feedback Source parameter determines the type of feedback used Digital Actuator Encoder Feedback This is the most common form of position feedback Most throttle controllers control the position of a Dyne Systems throttle actuator The actuator contains a digital encoder that provides position feedback to the throttle controller This feedback method is activated by setting the Feedback Source parameter to Digital Encoder Calibration ofthe digital encoder feedback signal is part of the overall actuator setup procedure described in section 7 2 Position Feedback Note The digital actuator encoder provides relative position feedback not absolute position feedback When power is first applied to the Dyn Loc V the position counter is reset to zero causing the Dyn Loc V to assume the actuator is at the 0 position It is therefore abs
137. limit however it makes no sense to enter a ramp rate higher than the control loop or the mechanical system can follow Up Down Ramp Rates and Master Computer Ramp Rates The Dyn Loc V maintains a set of ramp rates for each control variable A ramp rate set consists of an Up and Down ramp rate for Computer mode and another pair of Up and Down ramp rates for Master mode The Up ramp rate is used by the ramp rate processor when the commanded setpoint is higher than the current value of the ramped reference i e the ramped reference is ramping Up Similarly the Down ramp rate is used by the ramp rate processor when the command setpoint is lower than the current value of the ramped reference i e the ramped reference is ramping Down The Master Up Down ramp rates are used when the commanded setpoint comes from the front panel Master ramp rate values are always saved in non volatile memory Computer Up Down ramp rates are used when the commanded setpoint comes from a host computer Computer ramp rate values are NOT saved in non volatile memory hence the host computer should re establish them prior to each test Dyn Loc V User Manual General Controller Concepts 4 3 Chapter 4 Dynamometer Control 1 3 1 4 4 4 Bumpless Transfers The term bumpless transfer refers to a smooth transition of a controller from an off disabled state to an on enabled state It also refers to the smooth tran
138. lowed If the polarity of the current reading is incorrect the configuration of the respective control variable should be changed in order to correct the polarity Do not attempt to correct the polarity by entering span values of opposite sign 131 Span count must When calibrating the actuator low and high limits the actuator be 10000 span count value i e the difference between the encoder count value at 100 and the encoder count value at 0 must be at least 10 000 counts If a smaller range of travel is required slide the throttle cable connection down the actuator arm 1 e move it closer to the center ofthe actuator NOTE This error only applies to throttle actuators using digital encoder feedback 132 Span count must When calibrating the actuator low and high limits the actuator be 57000 span count value i e the difference between the encoder count value at 100 and the encoder count value at 0 must be less than 57 000 counts If a larger range of travel is required slide the throttle cable connection up the actuator arm i e move it away from the center of the actuator NOTE This error only applies to throttle actuators using digital encoder feedback 133 Span voltage When calibrating the actuator low and high limits the span must be gt 2 0 voltage value 1 e the difference between the position voltage at volts 100 and the position voltage at 0 must be greater than 2 volts NOTE This error only
139. m sec Gravitational acceleration metric 32 17404856 ft sec Gravitational acceleration 3 14159265 PI 7 2 Conversion Factors Value Units Type 12 in ft length 5280 ft mi length 2 54 cm in length 25 4 mm in length 1 609344 km mi length 60 sec min time 60 min hr time 16 oz lb weight or force 0 22480894 b N weight or force 0 73756214 Ib ft N m torque 14 59390205 kg slug mass 1 355817866 kg m slug ft rotational inertia 32 17404856 Ib ft slug ft i e G rotational inertia 0 145038 psi kpa pressure 0 491159 psi in Hg pressure 0 0193368 psi mm Hg pressure Dyn Loc V User Manual Constants and Conversions Reference 13 41 Chapter 13 Reference 8 0 Acronyms 13 42 Acronym Definition A D Analog to Digital Converter BSTOP Brake Stop CV Control Variable D A Digital to Analog Converter EC Eddy Current EC PAU Eddy Current Power Amplifier Unit ESTOP Emergency Stop GPIO General Purpose Input Output ILK Interlock LOSF Loss of Speed Feedback LPF Low Pass Filter MAG PU Magnetic Pickup MAP Manifold Absolute Pressure OCS Operator Control Station PAU Power Amplifier Unit PID Proportional Integral Derivative PLC Programmable Logic Controller PPR Pulses Per Revolution RTZ Return to Zero THR PAU Throttle Power Amplifier Unit TPS Throttle Position Sensor VAC Vacuum Acr
140. mand inputs allows digital control to be used simultaneously with other controller command interfaces e g a standard Dyn Loc V front panel Can be used simultaneously with the existing simple digital control of the dynamometer controller via the use of programmable digital inputs see Note below Occupies one back panel slot PLC level inputs i e 24 vdc Dry contact relay outputs Includes additional ESTOP and RESET inputs and outputs providing a one connector interface to an external controller Note Simple digital control of just the Dyn Loc V is already available as a standard feature of the Dyn Loc V see Chapter 4 section 6 0 But due to the limited number of available Programmable Digital Input PDI bits on the GENERAL PURPOSE I O connector it is not possible to control both the Dyn Loc V AND an optional throttle controller The optional Digital Control Card expands the digital I O capability of the Dyn Loc V allowing both controllers to be externally controlled while leaving the existing PDI s to be used for other important test cell safety functions Chapter 12 Digital Control Card 2 0 3 0 3 1 Installation The DIGITAL CONTROL back panel board and the accompanying internal interface board must be installed at the factory field upgrades are not recommended The Digital Control Card i e DS607 card is always installed in Slot 3 just above the General Purpose I O card which always occupies Slot
141. mmable digital input bits One bit is used to control the ON OFF state of the dyno controller while a second input bit is used to control the TORQUE SPEED mode of the dyno controller These input bits are edge triggered allowing digital control to be used simultaneously with the usual control interfaces Note An optional Digital Control card is available as a purchased option This card expands the available digital I O in the Dyn Loc V allowing the dyno controller and an optional throttle controller to be externally controlled This optional feature is fully described in Chapter 12 Setup The following parameter settings are required to properly configure digital control of the dyno controller card One programmable digital input bit must be configured with an input function of Digital Control ON OFF Select This input will then be used to issue enable disable requests One programmable digital input bit must be configured with an input function of Digital Control Torque Speed Select This input will then be used to issue mode change requests Operation The digital control inputs are edge triggered The operation of each bit is described below Input Transition Action ON OFF Select Rising edge Issue an enable request to the dyno controller If the controller is already enabled the rising edge is ignored ON OFF Select Falling edge Issue a disable request to the dyno controller Tf the controller is already
142. mmable input All lt function 1 gt choices are summarized in the tables that follows Default lt function 2 gt selection None lt function N gt 1 Invert polarity Yes No Invert polarity of input if necessary Input Functions Function Description Soft Shutdown This input is edge triggered A soft shutdown of all controllers is performed at the onset of the input being asserted A soft shutdown causes the dyno controller to be disabled and the throttle controller to return the actuator if any to the zero percent position Computer Watchdog Reserved for use by DyneSystems When Cell Assistant 2012 is running on a host computer the host computer watchdog module is wired into this input Used in simple systems were there is no other external safety logic where the watchdog module could be wired to NOTE When this input is selected the Computer Watchdog controller fault see Chapter 4 section 5 2 becomes active for each installed controller External Fault 1 Generates an External Input 1 fault for all installed controllers dyno or throttle This fault is described in Chapter 4 section 5 2 The actions taken in response to this fault are programmable Dyn Loc V User Manual Programmable Digital Inputs 8 7 Chapter8 General Purpose I O Card Function Description External Fault 2 Same as above except External Input 42 faults are generated Digital Control
143. mming tips will help ensure robust error free operation of the Digital Control interface e A proper command sequence is as follows 1 set the controller select bits mode select bits and enable disable bit 2 wait about 10 msec then 3 assert the ACTIVATE bit The Dyn Loc V samples all input bits simultaneously This sequence guarantees the command bits are stable by the time the ACTIVATE signal is detected Increase the delay time if the output bits on the external controller require additional time to stabilize After an ACTIVATE command is issued wait approximately 50 msec and then check the status of your command by reading and verifying the respective controller status bits as described in section 4 1 3 Controller disable commands will never fail and controller mode change commands are rarely rejected however controller enable commands are strictly checked and can easily fail if error conditions are present and or one or more input conditions are not correct The ACTIVATE input should be de asserted i e set to O VDC for at least 10 msec between successive commands Note As mentioned in several places in this chapter the digital outputs consist of dry contact relays These relays have a specified useful life of over a billion mechanical operations and thus if properly used should function properly over the life span of the entire Dyn Loc V box THEREFORE Do NOT change controller selections more often than necessary
144. n Chapter 7 Position calibration is described in Chapter 11 Calibration Selection Note Access to the Dyn Loc V calibration page will be denied if any controllers are currently enabled Note Calibration is a secured feature A password may be required to access the various calibration pages Security is discussed in Chapter 9 3 3 Numeric Keypad Buttons J 9 JL 2 12 These keys are used to enter numeric data e g setpoints ramp rates setup parameters etc on many dialogs All data entry will be entered into the appropriate edit box The Left Arrow button can be pressed to erase the previously entered key the CANCEL button can be pressed to erase the entire contents of the selected edit box Membrane Keypad Buttons Dyn Loc V User Manual Chapter 2 Operator Interface The arrow keys are used to navigate through the parameter tree during setup When appropriate the Left arrow button performs a Backspace function by deleting the previously entered numeric key Each of these examples and many more is explained in other areas of this manual ENTER The ENTER button provides many functions in various contexts For example pressing ENTER finalizes entry of a setpoint or other numeric data entry The ENTER button also duplicates the function of touch screen buttons in various situations In each case the function of the ENTER button should be obvious The CANCEL button is typically used to clear the entire contents
145. n Loc V User Manual 3 1 Chapter 7 Transducers Reference Source Selection There are two main types of reference sources digital commands and continuous analog inputs Digital setpoint commands are entered from the Dyn Loc V front panel or are sent to the Dyn Loc V via a serial connection e g the COMPUTER port This type of reference source is the most common type of reference source thus it is always listed first in the list of available reference sources and is the default selection set at the factory All of the remaining reference source selections are analog inputs Each installed controller card provides two configurable analog input objects Each will appear in the list as an available reference source input When an analog input is selected as the reference source the input is continuously scanned for setpoint references The controllers ability to follow the continuous setpoint values depends on how well the controller is tuned and is limited by the ramp rate value for the control variable A general list of available reference sources is shown below If an analog reference source is selected the input voltage must be properly scaled Input scaling for all types of control variables e g speed torque etc is described in section 3 3 The physical location of the voltage input for each controller Analog Input object is listed in Chapter 4 section 4 3 Path Dyn Loc V Control Variables lt Speed or Torque gt Ref
146. n can only be made when all controllers are disabled If manual A B selection is used this rule is enforced by default since all controllers must be disabled in order to access the Dyn Loc V setup page If shaft A B selections are made by Cell Assistant an error message will be returned if a running TestPlan attempts to change the shaft selection while any controllers are enabled Similarly if shaft A B selections are made by a programmable input the input bit is ignored while any controllers are enabled As soon as the last controller is disabled the input bit will be processed and the appropriate shaft selection will be made Dyn Loc V User Manual General Controller Concepts 4 7 Chapter 4 Dynamometer Control 1 9 3 Shaft Selection Annunciation The current shaft selection is reported to a host computer running Cell Assistant via a digital input channel Several programmable digital output source selections are also available see Chapter 8 section 5 0 such that external lamps can be wired to these outputs to annunciate the shaft A B selection of each dyno controller 4 8 General Controller Concepts Dyn Loc V User Manual Chapter 4 Dynamometer Control 2 0 Controller Setup Parameters Path WDyn Loc VV ID Parameter Values Description O Status ACTIVATED Activates or de activates the controller See DE ACTIVATED section 1 5 for the effects of de activating a controller Description DYNO Controlle
147. ne 1 Gain Adjustment 1 0 Output 2 0 Source None 1 Gain Adjustment 1 0 paes Output 3 0 Source None 1 Gain Adjustment 1 0 2 Offset Adjustment 0 Setup Parameter Hierarchy 2 Offset Adjustment 0 2 Offset Adjustment 0 Programmable Digital Outputs t t Programmable Analog Outputs volts volts volts Dyn Loc V User Manual Analog Inputs t Input 1 0 Offset Adjustment 1 Gain Adjustment 1 2 Input Filter None t Input 2 O Offset Adjustment 1 Gain Adjustment 1 2 Input Filter None 0 0 volts 0 0 0 volts 0 General Purpose I O 0 Ignore Master Enable Input Yes Programmable Digital Outputs fsa Output 1 0 Source None 1 Invert Polarity No q Output 2 0 Source None 1 Invert Polarity No pa Output 3 O Source None 1 Invert Polarity No dmm Output 4 0 Source None 1 Invert Polarity No Y Output 5 0 Source None 1 Invert Polarity No Pp Output 6 0 Source None 1 Invert Polarity No pe Output 7 0 Source None 1 Invert Polarity No q Output 8 0 Source None 1 Invert Polarity No deeem Output 9 O Source None 1 Invert Polarity No q Output 10 0 Source None Dyn Loc V User Manual Chapter 13 Reference Setup Parameter Hierarchy 13 7 Chapter 13 Reference 1 Invert Polarit
148. ne Sided Calibration 1 a A W N 7 8 9 10 Disassemble the test stand as needed Attach the calibration arm Attach the weight hanger to the calibration arm Perform a Zero calibration procedure section 2 4 3 Hang spanning weights on the weight hanger If necessary wait for the weights to stop swinging Compute the simulated torque value based on the amount of span weights and the calibration arm length Do NOT include the weight of the hanger or calibration arm since these values have already be zeroed out Perform a Span calibration procedure section 2 4 4 Remove the span weights hanger and calibration arm Perform another Zero calibration procedure section 2 4 3 Re assemble the system Two Sided Calibration 1 a A O N 12 13 14 15 Disassemble the test stand as needed Attach both calibration arms Attach the weight hanger to one of the calibration arms Perform a Zero calibration procedure section 2 4 3 Hang spanning weights on the weight hanger If necessary wait for the weights to stop swinging Compute the simulated torque value based on the amount of span weights and the calibration arm length Do not include the weight of the hanger or calibration arm since these values have already be zeroed out Perform a Span calibration procedure section 2 4 4 Remove span weights and hanger Attach the weight hanger to the opposite calibration arm Perform a Zero calibration procedu
149. nertia Units Select the dyno inertia units for the previously entered dyno inertia see Chapter 4 section 3 0 Indication When a controller is using estimated in line shaft torque the torque readout on the front panel display will change the respective readout label from Torque to In Line TQ This serves as a reminder to the operator that this controller is displaying and controlling an estimated torque measurement instead of a direct measurement from the transducer 3 0 Reference Sources 7 16 Controller setpoints typically come from one of two sources They usually are manually entered by an operator via the Dyn Loc V front panel Alternatively setpoints may be issued by automated control software and or other software programs running on a Host Computer The Dyn Loc V can also be configured to accept setpoint values from other sources Just as the feedback source of all control variables is configurable so is the setpoint i e reference source for all control variables The Setup parameters for each feedback transducer i e Speed Torque and Position contain a Reference Source parameter This parameter specifies the source of all setpoints when the respective controller is operating in the respective mode The list of all available reference sources is described below in section 3 1 The number and type of available selections depends on the number and type of installed controllers Reference Sources Dy
150. ng the OK button The Dyn Loc V Setup group of buttons provide access to the Dyn Loc V setup parameters The function of each button is explained below Button Function Modify Provides access to all Dyn Loc V setup parameters Pops up a dialog containing the standard parameter tree and parameter list as shown in Chapter 3 section 1 1 Text Dump Dumps a text version of all setup parameters to a file This file is for documentation purposes only A comprehensive list of parameters in presented in Chapter 13 section 1 0 was created using this feature Save To File Saves a binary version of all setup parameters to a file This file can be loaded into the Dyn Loc V later on if necessary Load From File Restores all setup parameters from a binary file Dyn Loc V User Manual Device Setup Pages 10 3 Chapter 10 Cell Assistant 3 0 Device Channels The Dyn Loc V device driver for Cell Assistant presents a large list of physical device channels to a running TestPlan Contact Dyne Systems for an up to date list of all device channels 10 4 Device Channels Dyn Loc V User Manual 1 0 2 0 Chapter 11 Throttle Control Overview An optional throttle controller can be added to the Dyn Loc V It consists of a second rack mounted enclosure containing a power amplifier unit to drive a throttle actuator motor as well as a second front panel display providing a dedicated throttle control operator inter
151. ni 3 Setup idco s oar AREA Ae NA RUN dA 3 Setup SoftWare eridelncxeg CEP cardenas as 4 Calibration AA paes Si LESS ein a aaa d Speed SCANS em TP Torque Feedback usus se mne Tagan iaa one SATA 5 Setup ParamietetS eec erid natn ae we P E EE EEES 5 Load Celie on aa ss ens a T T a a aes 6 WIDE o spas ea des E ias Siad SA es Sed ERR DIAS Ai Sds Spa Edo 6 TOC 4 Dyn Loc V User Manual Table of Contents SCUD cien atte ud A O ee sedie 7 In Line Torque Sensor ses oes oaa sue ER ee eee Ped V aX A es PES 7 WII cartera editan dardo cds 7 BEDID dec PP xut oN eS eae wean ee m aes t 4 Calibration cairo aia ESPERE TAE as ERES 8 1 Sided or 2 Sided Calibration 250302445 426555 sie eros debe de 8 Procedures A A Y Rd ad es da Rd 9 ERRO RDA EcL 10 SOI escitas taaan tiara tc 10 O Em cm 11 Shunt Calibration csssvspanisari cias cantas OHO A e EGRE 11 A 11 Shunt Calibration PrOCedute osos iaa a ea 13 Spanning to a Manufacturer Shunt Calibration Value 14 Multi point Torque Calibratiog 2222sioolkru Rep prr Pr RR ER ERA 14 Estimated In Line Shaft Torque 15 A v Sits bees Hoos ERAS SN b Er e EEE 15 Hardware Requirements coa dco 20259055 rOd EDT ars UK eng 16 CE cera ee ERU O edid ee 2 16 Indication sues AAA e wal Sods Rcx a 16 Reference SOUT CBSe 22092 ana sinia erbeoibeeiiosadc POP e vPEPSS 16 Reference source SCIOLI A EIA eed ET Reference Source IndicallOl s ss vues pe dadas e E X4 GO
152. nized to a button press or other operator action The error message text directs the operator towards a solution The Dyn Loc V may also return asynchronous errors and notifications these errors may appear at any time Asynchronous errors are sent when the Dyn Loc V detects an error condition that is not due to an operator action e g hard over speed fault The format of all error messages and notifications is displayed below nnn sss text nnn is a 3 digit error code This code should be used to look up the error in this manual if additional information 1s needed This code should also be referenced when contacting Dyne Systems for additional assistance sss indicates the source of the error It is typically blank It is set to THR if the error originated in the optional throttle controller The text field gives a brief single line explanation of the error Section 3 0 should be consulted for additional information Dyn Loc V User Manual Error Messages 13 15 Chapter 13 Reference 3 0 Error Codes Error codes are logically organized into the groups listed below Notification Codes 1 29 The Dyn Loc V returns these codes to the front panel display when it needs to be notified ofan event The operator interface usually needs to refresh various displayed values in response to these codes Error Code Text Description 1 Boot errors exist Issued when the Dyn Loc V is initially powered up and on
153. nt This control type is identical to the previous control type 1 e Position Cmd Motor except that operation in all 4 quadrants is allowed The following modifications are made to the by wire position control architecture in order to accommodate 4 quadrant operation The Control Output Type parameter must be set to Position Cmd gt Motor 4 Quadrant Repeat all of the other settings as described in the previous section The commanding of negative speed setpoints is allowed Attempts to enter negative speed setpoints normally results in a returned error message The commanding of negative positions i e torque commands is allowed Position values are normally restricted to the range 0 to 100 but now the valid range is 100 to 100 Note A throttle controller operating in all 4 quadrants presents some interesting control decisions for the corresponding loading device 1 e the dyno controller The Dyn Loc V dyno controller works well with a spinner that is capable of spinning in both directions See Chapter 4 section 1 8 for information on 4 quadrant dyno control 5 5 Speed Cmd gt ECM Because an external device 1 e the ECM is responsible for speed control the ramped speed reference is output directly to the ECM using Feed Forward control methods see Chapter 6 section 5 0 Note When configured for by wire external speed control the throttle controller is permanently locked in speed cont
154. ntroller card Source Description Position Analog position reading Scaling is as follows Voltage Position reading in percent 10 0 Command Voltage position One programmable analog output with this source must be configured when the throttle controller is set up to output a Position command voltage By wire position control is described in Chapter 11 section 5 0 Command Voltage speed One programmable analog output with this source must be configured when the throttle controller is set up to output a Speed command voltage Several by wire speed control configurations are described in Chapter 11 section 5 0 Command Voltage speed This analog output is used in 4 quadrant by wire speed control configurations where the motor speed controller requires a unipolar speed command voltage and a digital speed sign bit See Chapter 11 section 5 0 for additional information 4 2 4 3 4 3 1 4 14 Programmable Digital Outputs The DYNO CONTROL connector on the dynamometer controller card provides 4 programmable PLC compatible digital outputs The function of each output is established by picking a function from a large list of available digital output control signals The configuration of these digital outputs is similar to the configuration of the digital outputs on the General Purpose I O card therefore please read Chapter 8 section 5 0 and follow the instructions given in t
155. ol feature They are described in the following notes Note After the Dyn Loc V is powered up the digital dyno control feature is completely disabled until a reset is issued This prevents any spurious activity on the inputs from being acknowledged until an operator and or higher level system software issues a reset In addition the reset itself will not be acknowledged for a period of 2 seconds after the Dyn Loc V has powered up Note All transitions of the digital command inputs must be sustained for a minimum of 50 milliseconds otherwise they will be ignored 4 22 Digital Control Dyn Loc V User Manual Chapter 4 Dynamometer Control 7 0 Theory of Operation 7 1 12 7 3 7 4 7 5 7 6 The Dyn Loc V is based on a classical Proportional Integral Derivative PID architecture Except for basic signal conditioning and electrical isolation the controller is entirely software based The next few sections describe the basic components of the dynamometer controller PID Controller The controller section implements a classical Proportional Integral Derivative PID controller It is entirely software based and is updated at a rate of 500 Hz Three PID tuning constants and an adjustable feedback filter are set during the tuning process The feedback filter is a digital low pass filter thirteen cutoff frequencies from 50 Hz to 0 25 Hz are available This filter can also be disabled Control Variable A control variable objec
156. olutely necessary that the actuator position be returned to the 0 position when the power to the Dyn Loc V is removed The Dyn Loc V handles this automatically It detects loss of power conditions and still has enough stored energy to return all actuators to the 0 position Regardless it is still a good operating practice to manually return all actuators to the 0 position prior to powering down the system Note Because the Dyn Loc V assumes all actuators are at the 0 position at power up it automatically returns all actuators to the 0 position when powering down the system see previous note It is extremely important then that the position ofthe actuator is NOT moved while the system is powered down If the actuator position is altered the actuator setup procedure section 7 2 must be performed to re establish the correct 0 and 100 position settings Dyn Loc V User Manual 6 2 2 6 2 3 Chapter 11 Throttle Control Analog Actuator Feedback If a digital actuator encoder is not available and or true absolute position feedback is required analog actuator position feedback can be used This feedback method is activated by setting the Feedback Source parameter to Analog Position Voltage The Input Voltage 100 and Input Voltage 0 parameters should be set to initially define the voltage range of the position sensor These values will be adjusted later on during actuator setup section 7 2 The analog in
157. on can be touched to re span the load cell This method is useful for making minor adjustments to the load cell span calibration due to sensor drift If the span has drifted a significant amount 1 e the previous shunt calibration values differ greatly from the new shunt calibration readings the load cell should probably be totally re calibrated in the usual manner see section 2 4 2 Note Touch the Save button before exiting this page to permanently save all calibration changes if any in non volatile storage Spanning to a Manufacturer Shunt Calibration Value When a manufacturer supplied calibration resistor is installed and a calibration data sheet for the load cell and resistor pair is available the following shunt calibration procedure can be used When the torque calibration page is displayed touch the Shunt CAL On button to apply the installed shunt calibration resistor The previously stored shunt calibration value if any is automatically placed in the Span edit box Press the Cancel button to clear the previous value and then enter the expected value from the manufacturers calibration data sheet Touch the Span button to complete the span calibration procedure Finally touch the Save button to permanently save the new calibration value Multi point Torque Calibration In order to satisfy the torque calibration requirements in the EPA Code of Federal Regulations CFR Title 40 Part 1065 310 the
158. onyms Dyn Loc V User Manual Chapter 13 Reference 9 0 Product Warranty WARRANTY REMEDIES AND LIMITATIONS Dyne Systems Inc warrants the following equipment will conform to published specifications and be free from faulty material or workmanship for the listed time period from date of shipment or onsite repair New Controls 12 Months Service Calls 3 Months Repaired Controls 3 Months This warranty covers properly installed equipment used within specified limits and ambient conditions and is limited to repair or replacement of equipment proving defective at Dyne Systems For warranty to be valid Buyer must conform to Dyne Systems factory specifications If applicable terms of Warranty Validation and Delivery Certification must be met for warranty to be valid This warranty does not apply to experimental developmental or non standard Goods and Products which are sold as is where is Dyne Systems shall not be liable for labor costs associated with removing reinstalling or delivering any equipment Transportation costs associated with delivering products to Dyne Systems under the warranty are the responsibility of the Buyer Transportation costs associated with returning products to the Buyer under the warranty are the responsibility of Dyne Systems If warranty service is deemed necessary and product i e controls small dynamometer etc can be shipped to Dyne Systems then it is expected that product be sent to Dyne Systems how
159. oot interval The two range labels are changed by entering the range value using the front panel keypad and then touching the respective label 6 4 Tuning Page Display Dyn Loc V User Manual Chapter6 Tuning Entering Setpoints While the controller is enabled a setpoint can be entered in the usual manner 1 e enter the setpoint value using the front panel keypad and then press the ENTER button Additionally two pre defined setpoints SP1 and SP2 can be defined They are set by entering the value using the front panel keypad and then touching the respective SP1 or SP2 button Once set the setpoints are issued by touching the respective send button located immediately to the left of each setpoint button The pre defined setpoint values are mainly used when Setpoint Cycling is enabled i e touch the Enable Setpoint Cycling checkbox When enabled SP1 and SP2 are alternately sent automatically at the rate specified by the Period setting Setpoint cycling is cancelled by 1 unchecking the checkbox 2 disabling the controller 3 manually issuing a setpoint by pressing the ENTER button or 4 manually issuing a pre defined setpoint by touching one of the send buttons Tuning The controller can be enabled disabled from the tuning page by pressing the ON OFF button on the front panel P I and D values are changed by entering the desired value using the front panel keypad and then touching the respective
160. orirartrciida e eR Peers 7 Shaft Selection Annunciation core da 8 Controller Setup Parameters 24 4225 paeckzeseke aes Shab SAS RA REREES 9 Dynamemeter Setup Parameters ce ocicssiciipaliros E X r nroa aineen 11 Controller Hard Waters ado rs ii 11 Programmable Analog Outputs i24 e e Re 9 e taras ERES 11 Setup Parameters 24 405s oesadenivesiedbiehiseericesizeyies ss 12 O tp t Scaling eo Su voor eae SOIN sa ETIN ES 12 Signal SoUrCES cs ve epU EAS suey Xx ERRARE as id e IA EX 12 Programmable Digital Outputs 22229 9002499559020IFSEERIAMES RESP 14 AMAS PUIS G Sr ts ada a A e o se RES pd aa 14 Input LOCAUONS s ss oua rita ean di as 14 linde n P PPCRPERPRIT rcc EDT 15 Setup Parameters ot IIA ADA 13 Connector SUMMATY ses 242 29 Rhee ene tas ta PR td n a 16 A ps stat nee shiners psd E 16 TORQUE T esa ah Oa SS ed Oa RAGE eS 16 ANALOG O ongs tuas sai AA Ra Fla ERTS 16 DYNOCONTROLD 1422x422 9998 Rides Ree RT ESRQIade m dore 16 ruo TTD PM I7 m Pr HP 17 Controller Operation a 255925 Perdida ire IeDePQPS shad ieestdetnees 18 Enabling the Controller v uid eae ei 18 Controller PANO caspa seda asas DR Ys E VA eS quet bd Tasa sse 18 Digital Control 2242250922 isast ba Xe bmOSRESSRPERU EP OPE e YR EP S 21 i r Per 21 Opera soraya apo ad REPRISE EP RP EE 21 Theory or Operation 222422505902 ide subd sipalhdos pieimeds isa ees 23 PID Controller ETC ii es Ae AS
161. oss of Actuator Encoder ILK Only applies to systems using an actuator and THR PAU for position control Occurs when the actuator encoder cable is disconnected Stalled A stalled fault is thrown if the throttle position movement rate is too low based on how hard the control loop software is trying to change the position This fault prevents damage to an actuator or THR PAU ifthe throttle cable or actuator are stuck Throttle PAU Power Fail Only applies to systems using an actuator and THR PAU for position control The THR PAU generates this fault when it senses a loss of input power The THR PAU and the Dyn Loc V each have enough stored energy to return the actuator to the 0 position 9 4 Soft Over speed Detection Soft Over speed detection is similar to Hard Over speed detection in that the throttle controller continuously checks the speed reading against a preset limit value however the reaction to a soft over speed is much less volatile Instead of causing controller faults ESTOP s etc a soft over speed condition simply returns the throttle to the zero position A Soft Over speed notification see Chapter 13 section 3 0 is also sent to all front panel displays The Soft Over speed Limit setup parameter establishes the speed threshold Detection can be enabled disabled by changing the value ofthe Soft Over speed Detection setup parameter Note Regardless of whether or not Soft Over
162. ote 1 Analog Input 2 I 5 10 volt input Common 10 Al Shield 15 Ai NOTES 1 Connect a 10K to 25K potentiometer to Common to create a unipolar adjustable voltage that can be used to drive an analog input Due to the input impedance of each analog input the maximum voltage available depends on the value of the potentiometer Several examples are listed below Analog input functions are discussed in Chapter 4 section 4 3 POT Value Voltage Range 10K Oto 9 660 volts 12K 0 to 10 207 volts 15K O to 10 819 volts 20K 0 to 11 509 volts 25K 0 to 11 968 volts 13 30 Connector Summary Dyn Loc V User Manual Chapter 13 Reference 4 1 4 DYNO CONTROL Type DB 25 female Signal Type Pin Description Dyno Error Output O 1 Error signal that controls the dyno Dyno Error Common 14 Ai Shield 2 Error signal shield Ai Reset O PLC 15 Dyne ON O PLC 3 ESTOP O PLC 16 From hardware ESTOP circuit Dyne ON O PLC 4 Supply Common 17 Pi Supply Common Coolant Interlock Delay allowed PAU ON Delay allowed PAU OK Delay NOT allowed Shield Current Feedback Common 20 Ai Current Feedback Input I 8 10 volt analog input Programmable Output 1 O PLC 21 Programmable Output 2 O PLC 9 Programmable Output 3 O PLC 22 Programmable Output 4 O PLC 10 Supply Common 23 Pi 24 volt supply I 11 1 of 3 pins At least one must supply power Supply Common 24 P
163. ovides a solution in the form of an Estimated In Line Shaft Torque calculation feature The dynamometer can be trunnion mounted and equipped with a much less expensive load cell that measures dyno reaction torque Shaft torque is then continuously estimated using the reaction torque measurements Theory An in line torque transducer measures the total load that a dynamometer exerts on a device under test e g an engine At each moment in time the total load always consists of three components Reaction torque of the dynamometer Inertial loading during periods of acceleration and deceleration Spinning losses due to bearing friction and windage On the other hand a load cell attached to a trunnion mounted dynamometer only measures the reaction torque of the dynamometer It does NOT measure the spinning losses or the inertial loads that are present The following equation describes the relationship between the torque measurements from a load cell vs the torque measurements from an in line torque transducer _ do T bine E Tr oadCell T f i SpinLosses o Inertial Load During periods of acceleration and deceleration i e non zero dw dt the Dyn Loc V software will compute the inertial load created by the dyno and add this value to the measured reaction torque in order to estimate the total shaft torque produced by the engine Dyno reaction torque 7 and speed w are measured by the respective torque and speed t
164. owing modifications are made to the by wire speed control architecture in order to accommodate 4 quadrant operation The commanding of negative speed setpoints is allowed Attempts to enter negative speed setpoints normally results in a returned error message The speed command voltage to the external motor speed controller is now a bipolar 10 volt output instead of the usual O to 10 volt output Note A throttle controller operating in all 4 quadrants presents some interesting control decisions for the corresponding loading device i e the dyno controller The Dyn Loc V dyno controller works well with a spinner that is capable of spinning in both directions See Chapter 4 section 1 8 for information on 4 quadrant dyno control Note When configured for by wire external speed control the throttle controller is permanently locked in speed control mode No other control modes are allowed The following parameter settings are required to properly configure a throttle controller for by wire speed control The Control Output Type parameter must be set to Speed Cmd gt Motor 4 Quadrant The Command Voltage 0 and Command Voltage 100 parameters see section 5 8 must be set based on the input specifications of the external motor speed controller Compute and set the value of the feed forward control parameter in the speed PID parameter set as described in Chapte
165. performing the zero calibration Note Touch the Save button before exiting this page to permanently save all calibration values in non volatile storage 2 4 4 Span 7 10 The gain of the torque transducer is corrected by hanging a known weight onto the calibration arm computing the applied torque entering this computed torque value into the calibration page and finally touching the Span button The torque reading should now read the simulated torque value The new Gain Correction Factor is also displayed If 2 sided calibration is enabled see section 2 4 1 this entire process can be repeated for torque readings in the opposite direction 1 e hang weights on the opposite side of the torque shaft Note The displayed torque reading may have a display filter applied see Display Filter property in section 2 1 If so make sure you wait several seconds for the torque reading to stabilize before touching the Span button Note Make sure all hanging span weights are motionless before performing the span procedure Note Set the Shunt Calibration to OFF while performing the span calibration unless specifically spanning to a factory shunt calibration value as described in section 2 5 3 Note Touch the Save button before exiting this page to permanently save all calibration values in non volatile storage Torque Feedback Dyn Loc V User Manual 2 4 5 2 5 2 5 1 Chapter7 Transducers Note
166. pper left corner of the dialog Use the Up and Down arrow keys to change the selection Touch the OK button to accept the parameter change touch the Cancel button to quit without making any changes Note The ENTER and CANCEL keypad buttons duplicate the function of the OK and Cancel touch screen buttons String This data type is simply a string of printable characters The maximum string length allowed depends on the parameter type the maximum length is typically 40 characters The following figure shows the pop up dialog for string data types The parameter name is displayed in the upper left corner of the dialog Dyn Loc V Setup Parameters Dyn Loc V User Manual Chapter3 Setup Basics DYNO Controller This dialog presents a virtual keypad for entering alphanumeric data and other printable characters Touch the CAPS key to access upper case letters Touch the Other button to access punctuation marks and other unique printable characters A Space bar is also available When done touch the OK button to accept the parameter change or touch the Cancel button to quit without making any changes Note The ENTER and CANCEL keypad buttons duplicate the function of the OK and Cancel touch screen buttons The CANCEL button must be pressed twice the 1st press clears the entered data and the 2nd press dismisses the dialog box Note The numeric keypad buttons can also be pressed to enter numeric strings Dyn Loc V User Manual D
167. put Button Enter I PLC 32 Remote OCS button input Lamp Accept O PLC 14 Remote OCS lamp output Button Soft Shutdown I PLC 33 Remote OCS button input Lamp Stalled O PLC 15 Remote OCS lamp output 5 volts O 34 Actuator encoder excitation Shield 16 De Common 35 De ILK I 17 Actuator encoder interlock input A I 36 Actuator encoder clock A A I 18 Actuator encoder clock A B I 37 Actuator encoder clock B B I 19 Actuator encoder clock B 13 34 Connector Summary Dyn Loc V User Manual Chapter 13 Reference 4 3 General Purpose I O Back Panel The pin descriptions of each connector on the back of the General Purpose I O back panel board DS802 board are described in the sections that follow 4 3 1 COMPUTER Type DB 9 female Signal Type Pin Description n c 1 n c 6 TX data O 2 Transmit data output CTS I 7 Clear To Send handshaking input RX data I 3 Receive data input RTS O 8 Ready To Send output n c 4 n c 9 Ground 5 Di 4 3 2 OCS 1 OCS 2 and OCS 3 Type DB 9 male Signal Type Pin Description n c 1 ESTOP chain 6 RX data I 2 Receive data input RTS O 7 Ready To Send output TX data O 3 Transmit data output CTS I 8 Clear To Send handshaking input n c 4 ESTOP chain 9 Ground 5 Di 4 3 3 24 VDC Type 3 pin power connector Signal Type Pin D
168. put position voltage typically comes from a potentiometer mechanically connected to the actuator shaft The voltage excitation for this potentiometer is not available from the Dyn Loc V instead it comes from the Dyne Systems THR PAU that should be used in this type of configuration TPS Sensor Position feedback can also come from a customer supplied throttle position sensor The TPS sensor is wired into the TPS connector on the back of the throttle controller A 10 vdc excitation voltage is also available from the TPS connector This feedback method is activated by setting the Feedback Source parameter to Throttle Position Sensor The Input Voltage 100 and Input Voltage 0 parameters should be set to exactly define the voltage range ofthe position sensor since no calibration procedure is available 7 0 Actuator 7 1 7 2 The most common output device is a Dyne Systems throttle actuator It also must be configured and calibrated i e set up as do the various input transducers mentioned in other sections The Dyne Systems throttle actuator contains a digital position encoder that provides the required position feedback of the actuator see section 6 2 1 In some instances actuator position feedback is provided by a potentiometer see section 6 2 2 Regardless of which position feedback method is used the same actuator setup procedure is used Mechanical Setup If the throttle cable is attached to the very en
169. r 6 section 5 1 One throttle controller programmable analog output see section 8 1 must be configured with a Source set to Command Voltage speed This analog output is wired to the external motor speed controller This output will provide the required bipolar speed command voltage SEE IMPORTANT NOTE BELOW Note Instead ofa simple bipolar speed command voltage some motor controllers require a unipolar speed command along with a digital sign bit The Dyn Loc V can accommodate these controllers An alternate programmable analog output source is available Command Voltage speed This analog selection outputs the absolute value of the speed command Then the sign of the actual speed command is available from a programmable digital output bit see Chapter 8 section 5 1 The Source of this output bit should be set to THR Is Commanding Negative Speed Dyn Loc V User Manual Control Output Types 11 7 Chapter 11 Throttle Control Optional Internal Speed Control If the external motor drive unit and associated speed controller provides poor speed regulation or provides no closed loop speed control at all the Dyn Loc V can provide additional speed control as explained in Chapter 6 section 5 2 5 8 By Wire Settings The following configuration parameters must be properly set when any of the by wire control output types are selected Path Dyn Loc V Throttle Controller By Wire Cont
170. r Enter any 39 character description 2 Active Parameter Set 0 Range 0 to 9 3 Calculated Power Units HP Units for power reading on the front panel WATTS KW 4 Calculated Power 10 Decimal point resolution for power reading Display Resolution 1 on the front panel 0 1 0 01 0 001 10 Hard Over speed Limit 0 0 Speed limit value for Hard Over speed fault Units are the same as configured for the speed reading Chapter 7 section 1 1 11 Hard Over torque Limit 0 0 Torque limit value for Hard Over torque fault Units are the same as configured for the torque reading Chapter 7 section 2 1 12 At Speed Threshhold 1 0 0 Speed threshhold 1 of 2 See Chapter 8 section 5 0 Programmable Digital Outputs for more information on how this parameter is used 13 At Speed Threshhold2 0 0 Speed threshhold 2 of 2 See previous item 14 At Speed Deadband 1 0 0 Provides hysteresis i e a deadband for At Speed Threshold 1 See Chapter 8 section 5 0 Programmable Digital Outputs for more information on how this parameter is used 15 At Speed Deadband 2 0 0 Speed Deadband 2 of 2 See previous item 16 Loss of Speed Feedback 1 0 Sets the amount of time in sec starting at Start Delay the onset of controller enable to when non zero speed feedback MUST be detected This delay gives high inertia systems a small amount of time to begin rotating without generating spurious Loss of Speed Feedback faults at the
171. r is controlling the input torque to the system it must also be disabled by some other means otherwise the BSTOP sequence may not be able to successfully slow the test system to a stop Atthe onset of a BSTOP request the dyno controller will attempt to bring the test system to a stop using the predefined braking force If the controller is already enabled and running when the BSTOP occurs the controller will switch to the BSTOP state If the controller is disabled at the onset of a BSTOP the dyno controller will enable itself and enter the BSTOP state While in the BSTOP state the dyno controller will apply the selected braking torque The selected braking torque will be applied until one of the following conditions occur The speed reading drops below 10 RPM The operator disables the controller i e presses the OFF button The operator issues a reset Note A special situation exists if the speed reading is already lt 10 RPM at the onset of the BSTOP In this case the dyno controller assumes the low speed reading may be caused by a broken or disconnected speed sensor and applies the configured BSTOP braking torque for a fixed 10 second period just to be safe An operator can still cancel the BSTOP state by pressing the RESET or OFF button on the front panel 4 Quadrant Operation In order to test electric motors in all 4 quadrants of operation i e spinning in both directions an optional throttle controller provides 4 qua
172. r to MAG Pickup Note The following parameters are ignored in MAG PU input configurations Direction Type if Encoder Invert Polarity Encoder Setup Hardware Single ended encoders require additional hardware setup Specifically a bias voltage must be established at the negative inputs of the Clock A Clock B and Index Pulse inputs This is done by installing shunts at jumper locations JP3 JP4 and JP5 A single turn potentiometer VR1 must then be adjusted to provide the proper bias voltage at each of the three inputs Contact Dyne Systems for assistance in determining the proper bias voltage as well as how and where this voltage can be measured during the adjustment procedure Note Shunts for jumpers JP3 JP4 and JP5 are installed at the factory as needed They are NOT typically provided if they are not needed Dyn Loc V User Manual Speed Feedback 7 3 Chapter 7 Transducers 1 3 2 Setup Software 1 4 1 5 7 4 An encoder speed transducer configuration is selected by setting the Transducer Type parameter to Encoder If the encoder provides direction information the Direction Type if Encoder parameter must also be set Calibration Speed inputs are digitally processed and require no calibration by an operator Speed Scaling In some test configurations the speed transducer is separated from the torque transducer by some form of mechanical speed increaser or speed decreaser Since
173. ransducers The dyno inertia parameter i e J resides with all of the other dynamometer setup parameters This inertia value is typically obtained from the dynamometer nameplate data or dynamometer data sheet Note The Dyn Loc V does NOT compensate for i e add in the spinning losses of the dynamometer since they are generally not known and are also typically insignificant compared to the inertial load component Dyn Loc V User Manual Torque Feedback 7 15 Chapter 7 Transducers 2 7 2 2 7 3 2 7 4 Hardware Requirements This feature requires a properly configured speed transducer and a properly configured and calibrated torque transducer The setup and configuration of various speed transducers is explained in section 1 0 The setup and configuration of a load cell the torque transducer is explained in section 2 2 Setup The following parameters must be properly configured in order to enable the calculated in line shaft torque feature Torque Calculation This parameter is typically set to None i e no special torque calculations are performed Select the Dyno Reaction TQ gt In Line Shaft TQ option to enable the computed in line shaft torque feature for this controller All torque readings for this controller will now display the estimated in line shaft torque see section 2 7 4 Dyno Inertia Enter the dyno inertia obtained from the dynamometer nameplate see Chapter 4 section 3 0 Dyno I
174. re section 2 4 3 Hang spanning weights on the weight hanger If necessary wait for the weights to stop swinging Compute the simulated torque value based on the amount of span weights and the calibration arm length Do not include the weight of the hanger or calibration arm since these values have already be zeroed out Perform a Span calibration procedure section 2 4 4 Remove span weights and hanger Remove both calibration arms Dyn Loc V User Manual Torque Feedback 7 9 Chapter 7 Transducers 16 Perform another Zero calibration procedure section 2 4 3 17 Re assemble the system 2 4 3 Zero The torque transducer torque offset with no calibration weights installed is cancelled out by touching the Zero button The torque reading should now read zero The new Offset Correction Factor is also displayed The Zero button can be touched as often as necessary to remove all torque offsets in the torque transducer Note The displayed torque reading may have a display filter applied see Display Filter property in section 2 1 If so make sure you wait several seconds for the torque reading to stabilize before touching the Zero button Note Zeroing is the process of removing torque offsets from the transducer ONLY It should NOT be used to remove residual force offsets from the mechanical system For example make sure all components move freely etc Note Set the Shunt Calibration to OFF while
175. re setup tree and places the cursor on the top level folder Note Because of the limited viewing space available it is often easier to collapse the entire setup tree and navigate to another parameter than to use the arrow keys to go from one folder to another Selecting a Parameter When you have selected the folder containing the parameter s you wish to modify press the ENTER key The cursor will move to the first parameter in the list The following keypad keys can now be used to navigate through the parameter list Moves the cursor to the previous parameter Moves the cursor to the next parameter owe Returns the cursor to the setup tree 1 5 1 5 1 3 4 When you have selected the parameter you wish to modify press the ENTER key or touch the Modify button An appropriate dialog will pop up that allows the parameter to be modified The various types of parameters and the associated dialogs that modify each data type are discussed in the next section Data Types Every Dyn Loc V parameter is stored as one of four possible data types Each data type and the dialog presented to modify it are discussed below Binary This data type is a logic value that can only have one of two possible values e g YES or NO ON or OFF etc The following figure shows the pop up dialog for modifying binary data types The parameter name is displayed in the upper left corner of the dialog Dyn Loc V Setup Parameters Dyn Loc V User Manu
176. re specified by Setup Force Units parameter 14 Load Cell MvV 4 000 Load Cell sensitivity Valid range is from 1 000 to 5 000 mV Volt 15 Load Cell Radius 1 0 Distance from load cell connection point to center of rotation Units are specified by Setup Length Units parameter 16 Setup Force Units LB Selects force units for OZ previous setup parameters N Kg 17 Setup Length Units IN Selects length units for FT previous setup parameters mm meters 18 Torque Calculation None Optionally compute in line torque from a dyno reaction torque reading See section 2 6 for more information 19 Invert Polarity 20 Reference Source Yes No All selections are listed in section 3 0 Invert polarity of torque signal if necessary Torque setpoints typically are entered by an operator using the front panel however other torque reference sources are available Alternate reference sources and the setting of this parameter are described in section 3 0 2 2 Load Cell 2 2 1 Wiring A 4 wire connection is used when the load cell is located a short distance from the TORQUE connector i e less than 50 feet A 6 wire connection is used when the load cell is located larger distances from the TORQUE connector 7 6 Torque Feedback Dyn Loc V User Manual 2 2 2 2 3 2 3 1 2 3 2 Chapter7 Transducers Setup A load cell configuration is selected by setting the Transducer
177. ridden by setting the Ignore Master Enable Input property to Yes see Chapter 8 section 2 0 Note The PAU OK and ILK digital input enable requirements only apply to systems using an actuator Controller Faults When enabled the throttle controller continuously checks for incorrect faulty and or dangerous input conditions When any of these conditions occur the throttle controller will throw a fault The controller actions that occur in response to each fault are programmable A typical fault action is to disable the controller return the throttle actuator to the zero position and generate an ESTOP Available fault actions and fault setup is discussed in Chapter 5 When one or more faults are thrown the fault indicator on each front panel will glow bright red Fault indication and a procedure for viewing existing fault conditions is discussed in Chapter 2 section 4 5 Nole Faultconditions are latched they only can be cleared by pressing the RESET button If fault conditions still persist they are re thrown Dyn Loc V User Manual Controller Operation 11 19 Chapter 11 Throttle Control Throttle Controller Faults The following table lists faults unique to the throttle controller Path NDyn Loc V Throttle Controller FaultsV Fault Loss of PAU OK Description 24 vdc is no longer present at pin 24 of the THROTTLE CONTROL connector This error is most likely due to a THROTTLE PAU hardware failure L
178. rol ID Parameter Values Description O Command Voltage 100 10 0 Defines the output voltage when 100 percent position or maximum speed is commanded Valid range is 15 volts Only used when the Control Output Type is set to one of the by wire configurations as described in section 5 0 NOTE When configured for one of the by wire speed control selections the Maximum Speed value is the value of the RPM Input Dynamic Range parameter see Chapter 7 section 1 1 NOTE Even though the value of this parameter can be set from 15 to 15 volts the actual output voltage is still restricted to 10 volts The 15 range merely provides better mathematical flexibility in the scaling equation Command Voltage 0 0 0 Defines the output voltage when 0 percent position or zero speed is commanded Valid range is 10 volts Only used when the Control Output Type is set to one of the by wire configurations as described in section 5 0 11 8 Control Output Types Dyn Loc V User Manual 6 0 Position Feedback 6 1 Setup Parameters Chapter 11 Throttle Control The throttle controller has a Position Control Variable object This object maintains all setup parameters that determine the feedback source scaling and display appearance of the position reading for respective throttle controller Path NDyn Loc V Throttle Controller Po
179. rol mode No other control modes are allowed Dyn Loc V User Manual Control Output Types 11 5 Chapter 11 Throttle Control 5 6 11 6 The following parameter settings are required to properly configure a throttle controller for by wire speed control e The Control Output Type parameter must be set to Speed Cmd gt ECM One throttle controller programmable analog output see section 8 1 must be configured with a Source set to Command Voltage speed This analog output is externally wired to the ECM The Command Voltage 0 96 and Command Voltage 100 parameters see section 5 8 must be set based on the input specifications ofthe ECM Compute and set the value of the feed forward control parameter in the Speed PID parameter set as described in Chapter 6 section 5 1 Optional Internal Speed Control If the ECM provides poor speed regulation or provides no closed loop speed control at all the Dyn Loc V can provide additional speed control as explained in Chapter 6 section 5 1 Speed Cmd gt Motor This particular control type should be selected when an electric motor is used as the prime mover device i e the spinner Because an external device i e the motor power amplifier and or associated controller is responsible for speed control the ramped speed reference is output directly to the motor controller using Feed Forward control methods see Chapter 6 section 5 0
180. rt Delay The Loss of Speed Feedback Start Delay sec parameter is 120 0 sec cannot exceed the specified value NOTE Allowing a controller to start with no detectable speed feedback for an extended period of time may cause permanent damage to one or more parts of the systems 106 Can t modify Some parameters cannot be modified for safety reasons They are READ only only displayed for information purposes parameter 107 Zero value not Zero is NOT a valid value for many parameters e g encoder allowed resolution 108 109 UNDEFINED 110 This fault cannot Some faults e g Throttle PAU Power Fail cannot be ignored be ignored for safety reasons This error is generated if an attempt is made to set the IGNORE property for non ignorable fault This error will also be generated if an attempt is made to cancel all available fault actions for a non ignorable fault At least one fault action must be specified Dyn Loc V User Manual Error Codes 13 21 Chapter 13 Reference Error Code Text Description 111 Max PAU ON Entered value must be less than 15 0 seconds timeoutis 15 0 sec 112 UNDEFINED 113 Incorrect Password entered is not correct Try again If the password is lost password or forgotten contact Dyne Systems 114 Password Password must be numeric characters must be digits 0 to 9 115 Password length Password must be 4 to 10 digits in length must be 4 to
181. ry and should rarely require recalibration The Set Date and Set Time buttons launch tools to set the system time and date in the controller The time and date are set correctly at the factory however time changes may be necessary due to time zone differences The controller maintains the correct time and date as part of 40CFR Part 1065 310 multi point torque calibration 2 10 Membrane Keypad Buttons Dyn Loc V User Manual Chapter 2 Operator Interface Set Time and Date Pages The Set Time and Set Date pages are shown below Their operation is self explanatory Dyn Loc V User Manual Membrane Keypad Buttons 2 11 Chapter 2 Operator Interface 3 2 2 Tune Press this button to tune the active controller mode for the controller A TUNE full featured tuning page will be displayed presenting a high resolution graph of the currently active controlled variable while simultaneously allowing the operator to adjust all tuning parameters Tuning is discussed in Chapter 6 Note Tuning is a secured feature A password may be required to access the tuning dialog Security is discussed in Chapter 9 3 2 3 Calibrate When this button is pressed the Calibration Selection dialog shown below is CALIBRATE displayed This dialog presents a button for every feedback variable that can be calibrated Touch the appropriate button to access the calibration page for the selected feedback signal Torque calibration is described i
182. s Encoder SPEED 12 0 9 amps available for all encoders Load Cell TORQUE 10 TPS Sensor TPS 10 Throttle controller only 13 38 Electrical Specifications Dyn Loc V User Manual Chapter 13 Reference 6 0 Version Tracking 6 1 6 2 6 3 6 3 1 The Dyn Loc V and the Front Panel Interface provide several hardware and software components that contain version numbers These version numbers are critical to the tracking of software fixes hardware modifications addition of new features etc This section provides information on how to view these numbers in the event they are requested of the customer by Dyne Systems service personnel Main Dyn Loc V Firmware The version number of the Dyn Loc V firmware is located in the root folder of the property tree Path WDyn Loc V System ID Parameter Values 0 Firmware Version X XXX Front Panel Interface Firmware The version number of the Front Panel Interface firmware is displayed on the Dyn Loc V Front Panel setup page as described in Chapter 2 section 3 2 1 Hardware Information Information regarding various Dyn Loc V hardware components is listed in the following folder This information is mainly used by DyneSystems service technicians Path Dyn Loc V System Hardware ID Parameter Values 0 CPU Type See section 6 3 1 1 EPLD Version Slot 1 DS606 board See section 6 3 2 2 EPLD Version Slot 2 DS606 board See sect
183. s Eddy Current Power Amplifier Unit EC PAU Dyn Loc V User Manual Theory of Operation 4 23 Chapter 4 4 24 Dyn Loc V User Manual 1 0 Chapter D Faults A fault occurs when the controller detects an incorrect undesirable and or dangerous input condition Most fault conditions are continuously monitored only when the controller is enabled however a few are continuously monitored regardless of the enable disable state of the controller When a fault is detected the controller responds by taking a configured fault action A unique fault action can be defined for each individual fault Controller Faults A complete list of dynamometer controller faults is presented in Chapter 4 section 5 2 similarly if an optional throttle controller is installed a list of throttle controller faults is presented in Chapter 11 section 9 3 Chapter5 Faults 2 0 Controller Fault Actions 2 1 There are several selectable fault actions that can take place when a controller fault is detected The available actions vary slightly between faults from the Dyn Loc V versus faults from an optional throttle controller Also there are some variances in available fault actions due to the type of fault All fault actions are listed in the tables that follow Note The individual occurrence of each fault is latched a reset must eventually occur to clear all latched fault conditions Note All fault actions occur only once at the onset of fault
184. sage Dyn Loc V User Manual Chapter 13 Reference Error Code Text Description 41 DLS is busy This error may occur if an operator tries to save setup data to processing a non volatile memory while a previous save is still in progress It previous should rarely occur and is harmless Simply wait a few seconds command and retry the command 42 Setpoint rejected Setpoints are only accepted when a controller is enabled It makes Controller NOT no sense to accept a setpoint if the controller is disabled since the enabled controller will do a bumpless transfer to a new setpoint when it is first enabled 43 Not allowed Some controller commands are not allowed when the respective when controller is controller is enabled Disable the controller and retry the original enabled command 44 Actuator RTZin Throttle controller enable disable and mode change commands progress are rejected when the actuator is currently in the process of returning to the zero position Wait for the RTZ to complete and retry the original command The RTZ action is probably the result of a fault so the fault may need to be reset before the original command can be retried 45 Position setup in Throttle controller enable disable and mode change commands progress are rejected when another front panel is currently in the process of calibrating the actuator position Wait until the actuator setup is completed and retry the original command
185. scriptions of each connector on the back of the dynamometer controller back panel board DS603 board are described in the sections that follow 4 1 1 SPEED Type DB 15 female Signal Type Pin Description Common 1 Encoder Excitation Common De Common 9 Encoder Excitation Common De 12 volts O 2 Encoder Excitation 900 ma available for all encoders 5 volts O 10 Seenote 1 A I 3 Differential Clock A or Single ended TTL Clock A A I 11 Differential Clock A B I 4 Differential Clock B or Single ended TTL Clock B B I 12 Differential Clock B Index I 5 Differential Index pulse or Single ended TTL Index Index I 13 Differential Index pulse MAGPU I 6 Differential MAG Pickup MAGPU I 14 Differential MAG Pickup MAGPU Shield 7 MAG Pickup shield connection Ai Shield 15 Additional shield connection De Shield 8 Additional shield connection De NOTES 1 The 5 volt regulator is optionally installed at the factory as needed 13 28 Connector Summary Dyn Loc V User Manual 4 1 2 TORQUE Type DB 25 male Chapter 13 Reference Signal Type Pin Description IN I 1 50 mV differential load cell input IN I 14 50 mV differential load cell input Shield 2 Differential load cell input signal shield Ai n c 15 Amplified Loa
186. setpoint edit box The Left arrow and CANCEL buttons can be used to make corrections The Left arrow deletes the previously entered digit The CANCEL button deletes all previously entered digits 1 e completely clears the setpoint edit box When done press the ENTER key to send the setpoint to the Dyn Loc V Note After a setpoint value has been entered either of the SET buttons can be pressed instead of the ENTER button to load the setpoint value into either set of virtual lever wheel switches Lever wheel operation is explained in section 4 3 The entered setpoint applies to the active control mode e g speed or torque of the controller If the setpoint is accepted the displayed setpoint value i e the value shown in parentheses in the lower right corner of the reading will be updated on the appropriate display reading and the setpoint edit box will be cleared in order get ready for another setpoint The setpoint may be rejected Check the message line for errors if this occurs The most common cause of a setpoint rejection is entering a setpoint while the controller is disabled Because the controller performs a bumpless transfer when first enabled it makes no sense to enter a setpoint while the controller is disabled Bumpless transfers are explained in Chapter 4 section 1 3 Note A non bumpless transfer can be performed when the controller is initially enabled by entering a setpoint and pressing the ON OFF button instead of t
187. shaft A shaft B operation A device can be coupled to shaft A and be tested while another device is being prepared for testing on dyno shaft B The dynamometer control loop and feedback software automatically inverts the speed and torque signals as needed when the controller is switched back and forth between shaft A and shaft B operation This allows a single load cell and speed transducer to be used for testing on either of the dyno shafts Shaft Selection Sources The shaft A B selection source is made by setting the Shaft A B Selection Source setup parameter listed in section 2 0 The following shaft A B selection sources are available Selection Source Description Shaft A Always Always use shaft A This is the default setting Allows the shaft A B selection to be made manually Shaft B Always Always use shaft B Allows the shaft A B selection to be made manually Cell Assistant Allow a host computer running Cell Assistant to make the shaft A B selection The Dyn Loc V Cell Assistant device driver provides a digital output channel allowing a running TestPlan to select shafts A and B as needed Programmable Digital Input The shaft A B selection is made via a programmable digital input see Chapter 8 section 6 0 on the GENERAL PURPOSE I O connector External PLC logic or an external button can be wired to this input to make the shaft A B selection 1 9 2 Shaft Change Restrictions The shaft A B selectio
188. shown below Connecting to DLS Connected 049 Ho active speed control exists 030 ESTOP exists The oldest message is at the top of the list followed by successively newer messages Touch the Clear button to clear the message queue and or touch the Done button to dismiss the dialog Note The message list is useful when diagnosing problems It is rarely used during normal operation of the Dyn Loc V because most error and status messages persist long enough in the Message Line for the operator to view them 2 18 Front Panel Operations Dyn Loc V User Manual Chapter 3 Setup Basics 1 0 Dyn Loc V Setup Parameters The Dyn Loc V contains hundreds of parameters that can be modified by an operator Most only need to be changed one time when the test environment is initially designed set up and tested Because of the large number of available parameters it is important for the operator to understand the organization of these parameters how to navigate through them to find the parameter of interest and how to change the selected parameter 1 1 Accessing the Dyn Loc V Setup Page The Dyn Loc V setup parameters are accessed as follows 1 Press SETUP The system displays the Setup Selection dialog box Setup Selection Front Panel Cancel Chapter3 Setup Basics 2 Touchthe Dyn Loc V button The system displays the main setup page e Control Variables amp 3 Faults a Parameter Sets amp
189. sition ID Parameter Values Description O Display Resolution 10 Decimal point resolution for position 1 reading on all displays 0 1 0 01 0 001 1 Display Units Units for position reading on all displays Percent is the only available selection 2 Display Filter None Amount of display filtering applied to 1 Sec Averaging position reading on all displays 2 Sec Averaging 4 Sec Averaging 8 Sec Averaging 10 Feedback Source Digital Encoder Analog Position Voltage Throttle Position Sensor Selects the type of position feedback being used See section 6 2 for more information 11 Actuator Direction Clockwise Counter clockwise Determines direction of rotation of an actuator if any This value specifies the desired rotation of the actuator as it moves from the 0 position to the 100 position 12 Input Voltage 100 10 0 Specify input voltage at 100 position if Feedback Source is set to Analog Position Voltage or Throttle Position Sensor If the throttle controller is controlling an actuator these values can be automatically set during actuator setup Dyn Loc V User Manual Position Feedback 11 9 Chapter 11 Throttle Control Parameter Values Description Input Voltage 096 0 0 Specify input voltage at 096 position if Feedback Source is set to Analog Position Voltage or Throttle Position Sensor If the throttle control
190. sition of an enabled controller from one controller mode to another When a controller is first enabled the Dyn Loc V reads the existing value ofthe feedback variable being controlled and uses the value as the first commanded setpoint The same process occurs when an enabled controller changes controller mode the Dyn Loc V reads the existing value of the NEW feedback variable to be controlled and uses the value as the first commanded setpoint This feature allows an operator to enable the controller and to switch controller modes quickly and confidently without having to worry about control loop glitches Locked Status An active control loop maintains a locked status at all times The controller is locked when the value of the controlled variable closely follows the value of the ramped reference in this case the LOCKED indicator on the front panel will turn on i e become bright red If the value of the controlled variable cannot follow the ramped reference input to the control loop the LOCKED indicator on the front panel will turn off When a controller is enabled the LOCKED indicator should be on at all times The control loop can become unlocked for several reasons Theramp rate value is too high Large ramp rate values cause the ramped reference input to the control loop to quickly follow large step changes to the commanded setpoint The control loop and or mechanical system may not be capable of responding quickly enough
191. source options are available OCS 1 OCS 2 and OCS 3 RS 232 serial port connections to throttle controller front panels remote front panels etc COMPUTER RS 232 serial port connection to a host computer See section 3 1 for more information NETWORK Network connection to a host computer See section 4 0 for more information General Purpose I O All programmable digital inputs section 6 0 and programmable digital outputs section 5 0 are present on this connector Other system wide controller signals are also present Dyn Loc V User Manual Connector Summary 8 9 Chapter8 General Purpose l O Card 10 0 Jumpers The GPIO board i e the DS802 board has the following jumpers that may require a shunt to be installed All shunts bypass complete the ESTOP chain as needed Jumper Function JP1 Install this shunt if nothing is connected to the OCS 3 connector JP2 Install this shunt if nothing is connected to the OCS 2 connector JP3 Install this shunt if nothing is connected to the OCS 1 connector JP4 Bypasses internal ESTOP IN 1 Factory use only JP5 Bypasses internal ESTOP IN 2 Factory use only JP6 If installed bypasses the ESTOP input on the GENERAL PURPOSE I O connector For simple systems with no external wiring on the GPIO connector install this shunt to prevent this input from continuously generating an ESTOP condition 11 0 Fuses F1 Install a 2A fast acting fuse BU
192. stem This Range 200 RPM value is used to scale Speed programmable analog 500 RPM output signals Select the lowest possible value that 1 000 RPM still includes the highest speed at which the system 2 000 RPM will operate 5 000 RPM 10 000 RPM 20 000 RPM 50 000 RPM 100 000 RPM 14 Speed Scaling 1 0 See section 1 5 Typically not used 1 e set 1 0 15 Invert Polarity Yes No Inverts the polarity of the speed signal for encoders only This parameter should be used if the encoder is mounted such that the normal direction of rotation produces a negative speed signal 7 2 Speed Feedback Dyn Loc V User Manual Chapter 7 Transducers ID Parameter Values Description 16 Digital Noise Filter None FOR FACTORY USE ONLY 96 000 Hz 48 000 Hz The speed measurement hardware contains 24 000 Hz specialized digital noise filtering logic that is only to 12 000 Hz be activated by Dyne Systems personnel as required 6 000 Hz an 3 000 Hz Default setting None 1 500 Hz 17 Reference Source All selections are Speed setpoints typically are entered by an operator listed in section using the front panel however other speed reference 3 0 sources are available Alternate reference sources and the setting of this parameter are described in section 3 0 1 2 1 2 1 1 3 1 3 1 Magnetic Pickup MAG PU Setup A MAG Pickup transducer configuration is selected by setting the Transducer Type paramete
193. t exists for each controller mode e g speed and torque The control variable object is responsible for input scaling and calibration of the feedback signal The scaled and calibrated input signal is then fed to the control loop The control variable object is also responsible for the display appearance of the feedback signal on Dyn Loc V front panel Display units display resolution and display filter parameters are all part of the control variable object for each feedback signal The display filter is a simple digital low pass filter D A Converter and Output Filter The dyno error signal is optically isolated and converted to a 10 volt signal using a 16 bit Digital to Analog converter The update rate is 500 Hz The error signal is filtered using a 2nd order 400 Hz low pass filter This filter removes most ofthe 500 Hz component and its associated harmonics from the final output signal Anti Alias Filter and A D Converter All analog inputs are optically isolated and digitized using a 16 bit Analog to Digital converter A 6th order 60 Hz low pass anti alias filter is used to aggressively eliminate all frequency components above 250 Hz i e one half of the 500 Hz sampling rate Frequency Measurement Logic The frequency measurement hardware can accurately measure the frequency of any encoder clock or magnetic pickup Quadrature direction measurement is also available EC PAU The dyno error signal is externally wired to a Dyne System
194. t panel is currently accessing setup parameters No run time commands e g enable disable will be accepted from any of the other front panels until setup is exited 38 DL5 in calibration mode All controller run time commands are rejected when the Dyn Loc V is in calibration mode This error occurs when multiple front panels are connected to the Dyn Loc V and one front panel is currently calibrating a transducer No run time commands e g enable disable will be accepted from any ofthe other front panels until calibration is exited 39 DL5 in factory setup mode All controller run time commands are rejected when the Dyn Loc V is in factory mode This error occurs when multiple front panels are connected to the Dyn Loc V and one front panel is currently accessing factory information No run time commands e g enable disable will be accepted from any of the other attached front panels until factory mode is exited NOTE Factory mode is only available to in house technicians at Dyne Systems This error should not occur at a customer site 40 13 18 Enabled controllers exist Error Codes Some operations are not allowed unless all controllers are disabled For example access to Dyn Loc V setup parameters is not allowed when any installed controllers are currently enabled Other operations such as accessing calibration changing the dyno shaft selection etc will also be rejected and report this error mes
195. t software has complete control regarding when this interface is activated Secondly the RESET itself will not be acknowledged for a period of 2 seconds after the Dyn Loc V has powered up Issuing Commands The definitions of all input bits are summarized below Input s Type Description CS1 CSO Level Provides the controller selection for the Enable Disable and controller mode commands that are issued when a rising edge is detected on the ACTIVATE input All possible values are listed below MD1 MDO Level Determines the new controller mode when a rising edge is detected on the ACTIVATE input All possible selections are listed below ENABLE Level Determines the Enable Disable state of the controller when a rising edge is detected on the ACTIVATE input 24 VDC Enable request 0 VDC Disable request ACTIVATE Edge When a rising edge is detected on this input the ENABLE and Triggered mode select bits 1 e MD1 MDO are sampled and then the appropriate Enable Disable and controller mode commands are issued to the selected controller specified by bits CS1 CS0 ESTOP Level Provides an additional ESTOP input similar to the ESTOP input on the GENERAL PURPOSE I O connector Apply 24 VDC to prevent an ESTOP condition from being asserted from this connector RESET Level Provides an additional reset input similar to the RESET input on the GENERAL PURPOSE I O connector Apply 24 VDC to assert th
196. ted at the factory and come with factory calibration data sheets that specify the exact output of the load cell when a specific shunt calibration resistor is applied These load cells can be spanned without any external weights or calibration hardware whatsoever when the manufacturer supplied calibration resistor is used during shunt calibration When JP2 is jumpered in the 2 3 position a manufacturer supplied precision resistor is used as the shunt calibration resistor This resistor must be soldered in place on the respective controller card Note Manufacturer supplied shunt calibration resistors are typically installed by Dyne Systems service personnel Contact Dyne Systems for instructions regarding how to install this resistor should it ever need to be replaced e g when the old load cell and calibration resistor must be replaced with a new set The shunt calibration procedure to be followed when using a manufacturer supplied calibration resistor is described in section 2 5 3 External Shunt Calibration Resistor Some torque transducers e g in line torque sensors have their own internal shunt calibration capability Each TORQUE connector on the back of the dyno and throttle cards has two external shunt calibration enable digital outputs that should be wired to the shunt calibration enable and shunt calibration enable inputs if any of the torque transducer Note When using an external shunt calibration resistor the JP
197. tents Chapter 1 Introduction Standard Pealures cs seotiresr reU v radar 1 IMA Sra reitera ras as dad pisa ri gts q 2 Front Panel ss rabo aa Dra de 2 Cell ASSISIADL i 5e rcr Ee rua RO TENER e sic per 2 Computer THIBEEIETHE seser africa sina sds as cdas das 2 Digital Control sis dos quas dus p ENT AT NEAN ES d ewe RE as DUI a d a ad 3 Notices 22 cav POU m 3 Daley A ed oe 3 Receiving InSpecHolb tata BARA 3 Damage Claims e sssrrsssisorsbisisna ade isto Fies iso Ra see dhe 3 jv CETT 4 Eleotracutien EIa2zatd vos dum a Wale das aS P ERG UN RA nA das ae Blectrostatic Discharge does ir evo 4 Rr Pe errores MISE SerVICINS P Document Conventions 20 05 a ess x RS LENTES DERE RUM d s dd 4 Chapter 2 Operator Interface Front Panel CORIDODOHDSS ves crece eres deerd mE ete das d 1 LCD Display with Touch Screen odas pre ER ERR o ES 2 Membrane Keypad 22 4525 299b wu ER ER E P S E P Pr E Rd Ed PX 2 Emergency Stop ES TOP Button escassas ind ess casadas pad RE 2 Main Controller Screen ss ses d be ERREUR RD be S Ad ue AS 3 Reading S Joyce de Re seed shoe diee Cane tees s see ss ee Tee wares seeded 3 Ba cketounud COM qu aee oa dci iren diode ac eom dulce recs dca doter od ede 4 Lever W heel Switches 22i ucesbue e EE RAN EIS E PERRA NS 4 liic 2 vie D EET 5 Message AA E aaa op eeiniee ds bus audi Eras uia E dis 5 Setpoint Entry 22s dace Sad mane ee tia raa a ee a e E 6 R mp Rates ss cetane teed shoe sigs ines d
198. ter a standard ethernet network connection additional serial port connections to remote displays general purpose programmable digital inputs and outputs for external interfacing and all hardware ESTOP circuitry Each is discussed in the sections that follow Note Every Dyn Loc V has exactly one GPIO card installed in Slot 4 the bottom slot 2 0 Setup Parameters The following setup parameters pertain to the GPIO card Chapter8 General Purpose I O Card Path Dyn Loc V General Purpose I O ID Parameter Values Description O Ignore Master No Assertion of Master Enable on the Enable Input Yes GPIO connector is an enable During ESTOP Only requirement for all controllers For simple systems with no external wiring on the GPIO connector this parameter can be set to Yes causing the Master Enable input to be ignored by all installed controllers The During ESTOP Only allows the controller to enable during ESTOP conditions without the presence of the Master Enable Signal 8 2 Setup Parameters Dyn Loc V User Manual 3 0 3 1 Chapter8 General Purpose I O Card Serial Port Connections COMPUTER Connection This connector is used to connect the Dyn Loc V to a host computer The required cable is a 9 conductor straight through cable with a 9 pin male DSUB connector at one end and a 9 pin female DSUB connector at the other end The baud rate of this port is programmable via the UART Baud
199. terface card is also available This card expands the available digital I O in the Dyn Loc V allowing both the Dyn Loc V and an optionally installed throttle controller to be externally controlled This is a purchased option and is fully described in Chapter 12 3 0 Notices 3 1 3 2 3 3 Safety To prevent physical injury follow all standard safety precautions when installing operating and maintaining the Dyn Loc V and all peripheral equipment Refer to the American National Standards Institute ANST or the Occupational Safety and Health Administration OSHA for additional safety information Follow all instructions in this manual Always remove all power to any component before attempting to access any internal components Obey all safety signs on the equipment and in this manual Receiving Inspection Upon arrival of your equipment check all items received against the packing slip to ensure the shipment is complete Inspect for damage or any evidence of rough handling as this may be an indication of hidden damage The following checks are offered to aid your inspection nspect packaging and skid s for any mistreatment Document and photograph any signs of damage Inspect housing to ensure there is no damage and that the unit is intact Damage Claims In the event of damage report it without delay to the Carrier and DS Dyne System s warranty policy does not cover shipping damage or lost material It
200. terface is described in Chapter 2 Cell Assistant Cell Assistant is a powerful data acquisition and control software package available from Dyne Systems This software product contains a device driver for the Dyn Loc V giving a Cell Assistant TestPlan access to all functionality of the Dyn Loc V The Dyn Loc V Cell Assistant driver is completely described in Chapter 10 Computer Interfacing In addition to Cell Assistant described above other methods of computer interfacing to the Dyn Loc V are available For example a set of LabView VT s are available in the Dyn Loc V LabView Software Developers Kit SDK allowing LabView programmers to create their own data acquisition and automated control applications using the Dyn Loc V Also the Dyn Loc V supports a limited set of ASCII commands that can be issued via the host computer serial port or network connection allowing simpler devices e g PLC s to communicate with the Dyn Loc V Contact DyneSystems for more information about these alternative programming interfaces Interfaces Dyn Loc V User Manual 2 4 Chapter1 Introduction Digital Control Two forms of external digital control are available Simple digital control is provided via the use of Programmable Digital Input bits Two bits can be defined to control the ON OFF state and the TORQUE SPEED mode of the Dyn Loc V Simple digital control of the Dyn Loc V is described in Chapter 4 section 6 0 An optional Digital Control in
201. tetatidxes e rr dai 9 COMPUTER a rta AAA AAA RARA 9 NETWORK sucinta kdo raa wx dx xo NUR ac a a ab ES a A 9 General Purpose VO osos oos rtorras 9 A A 10 j LOS pies hans rcr 10 Chapter 9 Security Setup Paramete S seces ragen aiae AR A DA A CAE q kee MUS d 1 Accessing d Secure System sas pre cidad 2 Changing the PassWord 220220225029 8 o2b keowsep sasbee hes dias ds 3 Secunng the Dyt D06 Vs cume iara da ene ne ANE REPAS ENRRAS AS Chapter 10 Cell Assistant LEVO as qua boa ias ada hend ide Sassi da haves eee Aro aida ed edu da 1 ai AAA 1 Controller Pages socia ads pa Paar RR Pd UP ERE alia 2 Calibration DADO sess isas eci iuar eieiaeo eaa baga ea e 2 SEMP Paes da Ee e E E E EA A REET GR a ee Kees aes 3 Device Channels us nseri daen ds DO DER AAA AAA 4 Chapter 11 Throttle Control QT RD MM 1 Connection to the Dyn Loc Ve cosscinicroro dada rr rara 1 Operator IMeraCS smsogarararda EE OD PU Rr VOX sa ed oes 2 Controller Setup Parameters ss ama iara a ga E AR 3 Control Output Types s ess esuker dk an Pietri 4 Dyn Loc V User Manual Table of Contents Aciiator gt EU IA bese nee ewes 4 Position Cmd gt ECM ssa iene s atado p GaGa ai 4 Position Cid gt MOLDE oc2ideeiv lt 4 P PIE REPRE raro 5 Position Cmd gt Motor 4 Quadrant 0 0 0 0 ce eee 5 Speed Cmd S ECM co ches cues edad heed Phebe Tas SKS a e 5 Speed CMA MOO rare eaa PEGA E A E rE E 6 Speed Cm
202. th WDyn Loc V System Network Port ID Parameter Values Description O IP Address 192 168 2 10 Static IP address of the controller The default value is listed but can be changed as needed 1 Subnet Mask 255 255 255 0 Subnet Mask Default value is listed and rarely will require a change 2 Physical Address NN NN NN NN NN NN Displays the ethernet address of the onboard network interface This is a read only value An IT department will need this value if the controller is connected to a network that relies on DHCP for IP address assignments 5 0 Programmable Digital Outputs The GENERAL PURPOSE I O connector provides 15 programmable PLC compatible digital outputs The function of each output is established by picking a function from a large list of available digital output control signals Note Redundant programmable outputs are allowed For example one two or all fifteen outputs can be configured to provide the same output function if necessary This can greatly simplify wiring if sufficient spare programmable outputs are available Instead of trying to crimp two or three wires into a single pin simply define two or three identical outputs and crimp one wire into each pin 8 4 Programmable Digital Outputs Dyn Loc V User Manual Chapter8 General Purpose I O Card 5 1 Setup Parameters The following setup parameters pertain to each programmable output Path Dyn Loc V
203. the Dyn Loc V is based on a classic Proportional Integral Derivative PID controller architecture A basic PID controller is shown below Tuning is the process of setting the PID constants Kp Ki and Kd and setting the amount of filtering on the feedback signal in order to achieve the desired transient and or steady state response Tuning is typically an inter active process The tuning dialog section 3 0 is displayed while the controller is enabled allowing the tuning parameters to be modified on the fly while the operator observes the transient and steady state responses Tuning can also be done off line If the required tuning parameters are known they can be entered directly from the setup page e m Kp A T Composite Reference o Eror Kgs Feedback Filter e Feedback fo Note Tips on PID tuning are beyond the scope of this manual Refer to other publicly available books and literature Chapter6 Tuning 1 0 Tuning Parameters 6 2 A set of tuning parameters is listed below Tuning is the process of setting these parameters Path Dyn Loc V Parameters Sets Set N Speed Parameters ID Parameter Values Description 0 IP 0 0 Kp constant Negative values not allowed E nr 0 0 Ki constant Negative values not allowed 2 ID 0 0 Kd constant Negative values not allowed 3 Feedback Filter 0 None Feedback filter cutoff
204. the speed measurement is not representative of the shaft speed at the torque transducer the displayed power reading is also not valid Speed scaling provides a simple mechanism to virtually i e mathematically relocate the speed transducer next to the appropriate torque transducer The displayed speed torque and power readings will now accurately represent a single location in the test stand The Speed Scaling parameter is listed in section 1 1 Note Speed scaling should affect how you interpret the speed input while setting many other configuration parameters As mentioned above speed scaling is used to virtually relocate a speed transducer and once it has been virtually relocated the operator should configure other parameters as if the transducer really has been relocated For example Hard Over speed limits and various At Speed thresholds should be set based on scaled speed readings Note Speed scaling is rarely used thus the Speed Scaling parameter should typically be set to 1 0 the default value Speed Feedback Dyn Loc V User Manual 2 0 Torque Feedback 2 1 Setup Parameters Chapter 7 Transducers Every controller has a Torque Control Variable object This object maintains all setup parameters that determine the feedback source scaling and display appearance of the torque reading for the respective controller Path Dyn Loc V Control Variables Torque ID Parameter Values Descr
205. this page to permanently save all shunt calibration values in non volatile storage Checking Span Calibration Since torque calibration should be checked frequently and since it is typically troublesome to disassemble the test stand and apply spanning weights the stored shunt calibration values can be used to periodically check the span calibration Return to the torque calibration page as often as needed with no spanning weights applied and the system in the normal operating configuration and touch the Shunt CAL On button This will re apply the electronic load to the load cell bridge network The previously stored shunt calibration value will be displayed along with a torque reading If the values match within acceptable tolerances touch the OFF button to remove the shunt calibration resistive load Touch the Done button to exit or touch the Shunt CAL On button to check the span in the opposite direction Dyn Loc V User Manual Torque Feedback 7 13 Chapter 7 Transducers 2 5 3 2 6 7 14 Re Span With Shunt Calibration Values When checking the span calibrations using the shunt calibration method notice that the stored shunt calibration values automatically appear in the Span edit box when the shunt calibration resistors are enabled This allows the load cell to be re spanned using the previously stored shunt calibration values While either of the shunt calibration resistors is enabled the Span butt
206. tion Speed Cmd gt ECM Speed Cmd gt Motor Speed Cmd gt Motor 4 Quadrant 11 Soft Over speed On Off Enable Disable Soft Over speed Detection detection See section 9 4 for more information 12 Soft Over speed 0 0 Soft Over speed limit Units are the Limit same as configured for speed reading 13 Mode Conflict Torque Selects the non speed mode that Default Mode Position this controller will be changed to during mode conflict resolution when this controller is being taken out of speed mode Dyn Loc V User Manual Controller Setup Parameters 11 3 Chapter 11 Throttle Control 5 0 Control Output Types 5 1 5 2 11 4 A throttle controller derives its name from the fact it typically controls the movement of an actuator that is mechanically linked to an engine throttle The throttle controller also supports configurations were the Dyne Systems actuator and throttle power amplifier unit THR PAU are replaced by a customer supplied external speed or position controlling device These devices accept a position or speed command voltage from the Dyn Loc V by wire and perform their own position and speed control This section discusses all of the output device configurations for a throttle controller Actuator gt Engine The most common output device is a throttle actuator It is typically linked to an engine throttle The throttle control loop software controls speed or torque by continuously adjustin
207. to be used The layout of the buttons and LED s on the Remote Station box is identical to those on the front panel This method should always be used if available since the Remote Station box is typically located near the actuator and or throttle mechanism allowing the operator to move the actuator while simultaneously viewing the position ofthe throttle Remote Station calibration is selected by touching the Remote Station button in the Setup Mode group This de activates all on screen setup buttons forcing the use ofthe Remote Station box Next follow the Local calibration procedure section 7 3 1 substituting the Remote Station buttons and LED s where applicable Manual Calibration Manual calibration is the easiest and quickest calibration method available It can be used with or without the existence of a Remote Station box however this method is the fastest if a Remote Station box is available Manual calibration is the same as the previously described position calibration methods except the THR PAU is disabled This allows the actuator arm to be moved manually i e by hand instead of using the UP and DOWN buttons The ENTER buttons on the front panel and the Remote Station box are still active so when the 0 percent and 100 percent positions are set either of these ENTER buttons can be pressed to accept the respective limit Manual calibration is selected by touching the Manual button in the Setup Mode group Th
208. ts The controller fault condition must be cleared before the enable request will be accepted Dyn Loc V User Manual Error Codes 113 17 Chapter 13 Reference Error Code Text Description 33 Master enable not asserted Requests to enable a controller are denied when the Master Enable input is not asserted The Master Enable input is an input pin on the GENERAL PURPOSE I O connector It must be tied to a 24 volt source directly or via a PLC for the enable request to be accepted NOTE The Master Enable input requirement can be bypassed as explained in Chapter 8 section 2 0 34 PAU OK not asserted Requests to enable a controller are denied when the PAU OK input is not asserted The PAU OK input is an input pin on the DYNO CONTROL and THROTTLE CONTROL connectors respectively It must be tied to a 24 volt source directly or via a PLC for the enable request to be accepted 35 UNDEFINED 36 Controller NOT in master mode Many controller commands e g mode changes enable disable etc from an operator are rejected if the controller is not in Master mode Press the Master Computer button to return the Dyn Loc V to Master mode then retry the original command 37 DL5 in configuration mode All controller run time commands are rejected when the Dyn Loc V is in configuration mode This error occurs when multiple front panels are connected to the Dyn Loc V and one fron
209. ttom As shown above the Power reading is ONLY displayed when the throttle controller is enabled When shown the Power reading is displayed immediately to the right of the Position reading overlaying several indicators and the message line Note The Power reading will temporarily disappear as needed if the message line needs to display an important operator message and or if any of the critical indicators e g ESTOP or FAULT become illuminated 11 2 Operator Interface Dyn Loc V User Manual Chapter 11 Throttle Control 4 0 Controller Setup Parameters These controller parameters are unique to the optional throttle controller Path Dyn Loc V Throttle Controller ID Parameter Values Description O Status ACTIVATED Activates or de activates the DE ACTIVATED controller See Chapter 4 section 1 5 for the effects of de activating a controller 1 Description DYNO Controller Enter any 39 character description 2 Active Parameter 0 Range 0 to 9 Set 3 Calculated Power HP Units for power reading on the front Units WATTS panel KW 4 Calculated Power 10 Decimal point resolution for power Display Resolution 1 reading on the front panel 0 1 0 01 0 001 10 Control Output Actuator Motor gt Engine Selects the proper control loop Type Position Cmd gt ECM structure based on output device Position Cmd gt Motor type See section 5 0 for more Position Cmd gt Motor 4 Quadrant informa
210. uiring the Cell Assistant product Contact Dyne Systems for more information When saving all setup parameters to a disk file the default file name is DLS Config dl5 Change the filename to something more descriptive and informative prior to saving however do not change the d15 file extension Note Transducer calibration data is NOT stored and retrieved along with the setup parameters thus whenever the Dyn Loc V setup parameters are restored from a disk file the existing calibration of all transducers remains as is Calibration is explained in Chapter 7 Top Structure of the Setup Tree It is important for the person or persons responsible for setup and configuration of the Dyn Loc V to become familiar with the organization of all setup parameters Complete familiarity with the organization of the setup tree will make it easier to locate parameters of interest as needed The top of the setup tree is shown below Parameter searches typically begin from this level since this is the initial tree state when the setup page is first displayed Nole Pressing the CANCEL button collapses the tree to the state shown below It is often easier to collapse the tree and start from the beginning when searching for and modifying several parameters E Dyn Loc V 4 43 Control Variables 1 23 Faults 1 23 Parameter Sets 1 43 Dyno Control 1 0 4 23 General Purpose 1 0 4 23 System 4 43 Throttle Controller 23 Dynamometer 1 23 Calibration Wei
211. undefined dcc Speed Parameters 0 0 0 0 0 0 3 Feedback Filter None 0 0 T Torque Parameters 0P 0 0 11 0 0 2 D 0 0 3 Feedback Filter None 4 FF 0 0 Set 1 0 Description undefined pee Speed Parameters 0P 0 0 11 0 0 2D 0 0 3 Feedback Filter None 4 FF 0 0 qe Torque Parameters 0P 0 0 11 0 0 2D 0 0 3 Feedback Filter None 4 FF 0 0 Set 2 0 Description undefined t Speed Parameters Chapter 13 Reference Setup Parameter Hierarchy 13 3 Chapter 13 Reference 13 4 0 0 0 0 0 0 DU Ho 0 0 Feedback Filter None FF 0 0 E NR O Torque Parameters 0P 0 0 11 0 0 2D 0 0 3 Feedback Filter None 4 FF 0 0 H Set 3 0 Description undefined Speed Parameters P 0 0 I 0 0 D 0 0 Feedback Filter None FF 0 0 SS UN Fr Oo Torque Parameters 0P 0 0 11 0 0 2D 0 0 3 Feedback Filter None 4 FF 0 0 L 4 Set 4 Description undefined Speed Parameters P 0 0 I 0 0 D 0 0 Feedback Filter None FF 0 0 E NR O Torque Parameters 0P 0 0 11 0 0 2D 0 0 3 Feedback Filter None 4 FF 0 0 r t Set 5 Description undefined Speed Parameters P 0 0 I 0 0 D 0 0 Feedback Filter None FF 0 0 SS UN FO Setup Parameter Hierarchy Dyn Loc V User Manual Chapter 13 Reference t Torque Parameters
212. urrently Hard Over speed configured over speed limit limit 13 20 Error Codes Dyn Loc V User Manual Chapter 13 Reference Error Code Text Description 69 Setpoint exceeds Torque setpoints are rejected if the value exceeds the currently Hard Over torque configured over torque limit limit 70 82 UNDEFINED 83 Setpointignored Setpoints from the Dyn Loc front panel are ignored when the Analog currently active control variable e g speed torque etc is using reference in use an analog reference source Reference Sources are described in Chapter 7 section 3 0 84 99 UNDEFINED Setup Errors 100 129 These errors are displayed when the Dyn Loc V is in setup mode and invalid parameter values are entered Error Code Text Description 100 Invalid character When entering a numeric value the only allowable characters are has been entered O through 9 and 101 No value entered The input value was blank 102 Negative value Negative values are not allowed for many parameters not allowed 103 Max coolantILK Allowing a dynamometer to run for more than 15 seconds with no timeoutis 15 0 cooling may cause permanent damage to the dynamometer sec 104 1 000 lt MvV lt When configuring a load cell the Load Cell Mv V parameter 5 000 must be in the specified range Load cell sensitivities outside the specified range are not supported 105 Max Sta
213. use or causes of the fault condition Dyn Loc V Faults 2 Loss of Speed Feedback Y Hard Over speed The first line ofthe list indicates the controller fault state ofthe Dyn Loc V The following icons are used to annunciate this state Fault condition exists O Fault condition does NOT exist If one or more controller faults exist the remaining lines in the fault list are a time ordered list of all the faults that have occurred since the last reset In general the first few faults and particularly the first listed are of the most interest since they generally indicate the root cause of a shutdown due to fault conditions Note Press the RESET button to try to clear all existing faults Dyn Loc V User Manual Front Panel Operations 2 17 Chapter 2 Operator Interface Many faults have an Ignore property When ignored faults occur they are still placed in the time ordered list of faults Ignored and not ignored faults are differentiated using the following icons Ignored Fault Y Active Fault Controller faults fault actions ignored faults etc is discussed in greater detail in Chapter 5 4 6 MessageList The message line lists the most recent error or status message from the Dyn Loc V In situations where several messages occur is quick succession only the last message can be viewed A queue of the previous 16 messages is maintained Touch the Message Line indicator to pop up a Message List dialog as
214. veral issues regarding ignoring faults are explained in section 2 3 5 2 Controller Fault Actions Dyn Loc V User Manual Chapter5 Faults Fault Actions List with ESTOP Action NOT Included Path Dyn Loc V Faults lt any fault ID Parameter Values Description O Dyno Controller Dyno OFF Select if the controller should be turned off or if Action Dyno OFF and Disable the controller should be turned off and then disabled i e cannot be turned on again until a reset occurs or none of these actions should occur 1 IGNORE overrides Yes No Use this setting to override the selected fault other settings action thus ignoring the specified fault Several issues regarding ignoring faults are explained in section 2 3 2 2 2 3 3 0 Throttle Controller Fault Actions The default action of an installed throttle controller to any detected fault is a Return to Zero RTZ In other words the throttle actuator arm is returned to the zero position and the controller is subsequently disabled Ignoring Fault Actions Some lists of fault actions include an IGNORE parameter The IGNORE parameter is used to temporarily ignore a fault without requiring an operator to disable the desired fault action and then possibly forget the original setting Note Some faults cannot be ignored for safety reasons e g Throttle PAU Power Fail For these faults the IGNORE parameter is not present Controller F
215. vice is damaged or destroyed all setup parameters can be restored after the hardware is repaired Recover from accidental parameter changes The Dyn Loc V has built in security features to prevent unauthorized personnel from changing setup parameters however if parameters are still accidentally changed for any reason they can be restored from the disk file Support of multiple hardware configurations The Dyn Loc V can be completely configured to run a test using a specific set of transducers When done all setup parameters can be saved to a disk file The Dyn Loc V can then be totally reconfigured to run a different test using a completely different set of transducers Then the new setup parameters can be saved to another disk file Afterwards the Dyn Loc V can easily and quickly be reconfigured by reloading either of the previously saved setup files The software application that provides the backup restore capability explained above is called Cell Assistant This application runs on a Windows computer It communicates via a serial cable connected to the COMPUTER port on the back of the Dyn Loc V Alternately Cell Assistant can be connected to the controller using the NETWORK connector also on the back of the Dyn Loc V See Chapter 10 for information on Cell Assistant Dyn Loc V Setup Parameters Dyn Loc V User Manual 1 8 Chapter3 Setup Basics Note Another backup restore software utility is available to customers not req
216. well as controller status for the controller specified by the Controller select input bits CS1 CS0 Details regarding the operation of each output is explained in more detail in section 4 1 Outputs Pin Function Output 1 20 Mode status bit 0 Output 2 8 Mode status bit 1 Output 3 21 CONTROLLER FAULT status Output 4 9 ENABLE status Output 5 22 lt notused gt Output 6 10 OK to RUN status Output 7 23 RESET status Output 8 11 ESTOPPED status Dyn Loc V User Manual Selecting an Interface Configuration 12 3 Chapter 12 Digital Control Card Note The previous tables only list the functions of the Input and Output bits All pins on the DIGITAL CONTROL connector are shown in Chapter 13 section 4 4 1 3 2 2 Push Button Control This Interface Type is not as flexible at the previously described Interface Type i e Computer Control This Interface configuration assumes all digital inputs are directly wired to momentary push buttons and all digital outputs are directly wired to simple illuminated annunciators The function of all input bits are listed below All inputs are edge triggered On the rising edge of each input i e the onset of a button press the appropriate command is sent to the respective controller Note that the ON OFF toggle commands require knowledge of the existing controller state similar to pressing the ON OFF button on the Dyn Loc V front panel Details regarding t
217. y No E Output 11 0 Source None 1 Invert Polarity No Output 12 0 Source None 1 Invert Polarity No Output 13 0 Source None 1 Invert Polarity No pon Output 14 0 Source None 1 Invert Polarity No poo Output 15 0 Source None 1 Invert Polarity No Programmable Digital Inputs t Input 1 0 Function None 1 Invert Polarity No t Input 2 0 Function None 1 Invert Polarity No t Input 3 0 Function None 1 Invert Polarity No t Input 4 0 Function None 1 Invert Polarity No t Input 5 0 Function None 1 Invert Polarity No System 0 Firmware Version 3 009 1 Minimum Reset duration 0 25 seconds q Security Secure Mode Off Password o kckckckckck kk ck Secure SETUP Yes Always Secure CALIBRATE Yes Secure TUNE Yes Powerup Secure Mode Off Oe WN FO 13 8 Setup Parameter Hierarchy Dyn Loc V User Manual Chapter 13 Reference q Hardware CPU Typ PCM VDX 1 256 ST PLD Version Slot 1 DS606 board 1 EPLD Version Slot 2 DS606 board 1 EPLD Version Slot 4 DS605 board 1 w NH o x1 ll p ett Computer Port 0 Baud Rate 115200 Network Port O IP Address 192 168 2 10 1 Subnet Mask 255 255 255 0 2 Physical Address 00 01 45 03 FA AC Throttle Controller O Status ACTIVATED
218. yn Loc V Setup Parameters 3 7 Chapter3 Setup Basics 1 6 Saving Setup Parameters Touch the Save button in order to save ALL setup parameters to onboard non volatile memory Do this as often as necessary to avoid accidental loss of parameter changes Parameter changes take affect immediately after they are made however if the changes are not saved to non volatile memory they will be lost when power to the Dyn Loc V is removed Note In some situations it may be desirable to make temporary parameter changes and deliberately NOT save the changes to non volatile memory The Dyn Loc V power can then be cycled in order to remove the temporary changes and thus restore all parameters to their original state Note Touching the Save button saves ALL setup parameters to non volatile memory Itis not possible to make several temporary parameter changes and then later try to make and save some permanent parameter changes Pressing the Save button at this time will save ALL previous changes to non volatile memory Note Multiple sets of setup parameters can be saved to and restored from external disk files This is explained in the next section 1 7 Backing Up and Restoring Setup Parameters 3 8 The entire contents of non volatile memory i e all setup parameters can be saved to and restored from a disk file if necessary There are several reasons to do this Recover from catastrophic hardware failure If the non volatile memory de

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