Woodward APECS 4500 User Manual
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Woodward APECS 4500 User Manual

Woodward APECS 4500 User Manual

Electronic engine speed governing system
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SE-4097
®
APECS
4500 Electronic
Engine Speed Governing System
User Manual
Manual SE-4097

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Summary of Contents for Woodward APECS 4500

  • Page 1 SE-4097 ® APECS 4500 Electronic Engine Speed Governing System User Manual Manual SE-4097...
  • Page 2 NOTE—provides other helpful information that does not fall under the warning or caution categories. Woodward Governor Company reserves the right to update any portion of this publication at any time. Information provided by Woodward Governor Company is believed to be correct and reliable. However, no responsibility is assumed by Woodward Governor Company unless otherwise expressly undertaken.

  • Page 3: Table Of Contents

    ACT Menus & Options ..................23 ACT Menu Structure ..................23 File Menu ......................23 Purpose......................23 Save APECS Cal to File ................24 View Cal File Comments ................25 View Text File ....................25 Convert Commands..................26 Convert APECS Cal to Text................26 Convert Cal File to Text ................26 Woodward...
  • Page 4 Diagnostics Calibration Parameters ..............57 Engine Protection Input.................57 Overspeed / Underspeed Protection.............58 Overspeed FAQ ....................59 Actuator Output Calibration Parameters...............59 Actuator Current Protection ................59 Auxiliary Outputs ...................62 Droop Governing...................63 Calibration Setup & Configuration Parameters Flowchart ........64 5. T ..............68 HAPTER ROUBLESHOOTING General Checklist ....................68 Woodward...
  • Page 5 ..............71 HAPTER ERVICE PTIONS Product Service Options ..................71 Replacement/Exchange................71 Flat Rate Repair....................72 Flat Rate Remanufacture................72 Returning Equipment for Repair ................72 Packing a Control..................72 Return Authorization Number ...............73 Replacement Parts ....................73 How to Contact Woodward...................73 Engineering Services....................74 Technical Assistance....................75 Woodward...

  • Page 6: Electrostatic Discharge Awareness

    PCB from the control cabinet, place it in the antistatic protective bag. CAUTION To prevent damage to electronic components caused by improper handling, read and observe the precautions in Woodward manual 82715, Guide for Handling and Protection of Electronic Controls, Printed Circuit Boards, and Modules. Woodward...

  • Page 7: Chapter 1. General Information

    APECS is suitable for use on both compression ignition (diesel) and spark ignition (gasoline, CNG, LPG) engines. Woodward developed the APECS system for a variety of on- and off-highway applications. Typical applications include generator sets, compressors, construction machinery and farm vehicles.

  • Page 8: System Components

    (e.g., flywheel). The universal speed input of the APECS 4500 is compatible with the following types of speed input signal: •...

  • Page 9: Actuator

    NOTE The scope of this manual does not include selection and installation of speed sensors, actuators, or linkages that Woodward offers for use with the APECS system. Information is available on our website at www.woodward.com.
  • Page 10 Manual SE-4097 Programmable Features The APECS 4500 expands Woodward’s line of programmable engine governors to address the needs of the mobile equipment industry. Enhanced input and output capability, combined with a flexible configuration, permits the controller to easily adapt to a wide variety of engine governing applications.

  • Page 11: Features Table

    4500 Electronic Engine Speed Governing System Features Table All features available with the APECS 4500 can be easily installed and configured to work with your application. Refer to the table below to determine if additional hardware installation is required. Software setup is always required to properly configure the feature.

  • Page 12: Engine Speed Select Options Table

    APECS 4500 Electronic Engine Speed Governing System Manual SE-4097 Engine Speed Select Options Table The following speed select options are available with the APECS 4500. SPEED SELECT OPTIONS NO ANALOG INPUT Use a speed switch to select up to 4...

  • Page 13: Chapter 2. Installing The Hardware

    Engine Protection Input page 19 Wiring Guidelines APECS 4500 has two 12-pin Deutsch connectors labeled J1 (grey) and J2 (black). Mating connectors may be purchased from Woodward (part number SA-4490) or from a Deutsch distributor. Deutsch part numbers are as follows:...

  • Page 14: Wiring Length

    15 ft (4.6 m) 0300 46 ft (14 m) 23 ft (7 m) 15 ft (4.6 m) (*) The controller has a working range of 9-30 VDC. However, the actuator must be selected for either 12 or 24 VDC charging system. Woodward...

  • Page 15: Controller Installation

    ® Manual SE-4097 APECS 4500 Electronic Engine Speed Governing System Controller Installation Controller Wiring The controller can be installed in the engine compartment (maximum temperature 185° F / 85° C.) Figure 2. APECS 4500 Dimensions Woodward...
  • Page 16 Switch to V Power Take-off RPS (J2-1) Not Used Rack Position Sensor RCV (J1-12), TXD (J1-1), V (J1-11), — ACT Connector GND2 (J1-2) RPM+(J1-10), RPM-(J1-3) — Speed Signal Input SW1 (J2-7), SW2 (J2-8), V (J1-9) Switch to V Switched Inputs Woodward...

  • Page 17: Controller Pinout

    VBAT (10 amp) VBAT (J1 9) Power (DC) Engine Protection Input GND (J1 4) EPSW (J2 9) Switched to Twisted Pair Wire Ground (> 1 twist per inch) RPS (J2 1) (not used) Figure 3. APECS 4500 Wiring Diagram Woodward...

  • Page 18: Speed Sensor Installation

    APECS 4500 Electronic Engine Speed Governing System Manual SE-4097 Speed Sensor Installation Guidelines There are four different speed-sensing devices that can be used with the APECS 4500 system. 1. Magnetic pickup 2. Spark ignition 3. Magneto 4. Hall Effect sensor Refer to Table 2 and Figure 3 for guidance in selecting the speed sensor suitable for your controller and application.

  • Page 19: Actuator & Linkage Installation

    (shutdown or idle) positions. Figure 5. Actuator Wiring NOTE: It is beyond the scope of this manual to discuss detailed actuator selection and installation procedures for all possible applications. Please contact the factory for specific information concerning your application. Woodward...

  • Page 20: Engine Speed Setpoint Wiring-Analog Input

    Engine Speed Setpoint Wiring—Analog Input Guidelines The APECS 4500 controller features an analog speed input for mobile or stationary applications. To incorporate this feature, wire the analog input to an external pot (which must be connected to a pedal). Use Figures 6 & 7 as a guide to wire the input to your application.

  • Page 21: Engine Speed Setpoint Wiring-Switched Inputs

    Engine Speed Setpoint Wiring—Switched Inputs Guidelines The APECS 4500 controller has two switched speed inputs for multiple speed settings. This is convenient for customers who need more than one speed for engine governing (i.e., idle speed/power speed setting or low power/high power setting).

  • Page 22: Power Take-Off Input Wiring

    Power Take-off Input Wiring Guidelines The APECS 4500 controller offers a Power Take-off (PTO) feature that allows the controller to switch from pedal input to switched inputs for mobile applications. Alternately, the PTO input may be configured for the autocrank feature.

  • Page 23: Glowplug Wiring

    APECS 4500 Electronic Engine Speed Governing System Glowplug Wiring The APECS 4500 offers a glowplug feature for remote or automatic starting of certain engines and applications. Either of the two auxiliary outputs may be configured for glowplug operation. Wire the glowplug relay on the engine to either of the controller auxiliary outputs (low side drivers).

  • Page 24: Autocrank Wiring

    4500 Electronic Engine Speed Governing System Manual SE-4097 Autocrank Wiring The APECS 4500 offers an autocrank feature for remote or automatic starting of certain engines and applications. Either of the two auxiliary outputs may be configured for autocrank operation. Wire the crank motor relay on the engine to either of the controller auxiliary outputs (low side driver).

  • Page 25: Engine Protection Input Wiring

    Figure 12. Typical Relay Wiring Engine Protection Input Wiring Optional Feature The APECS 4500 controller offers an engine protection shutdown feature to safeguard against adverse operating conditions such as low oil pressure or high coolant temperature. The engine protection (EP) input is a switched input similar to the set speed inputs. This input must switch to ground potential.

  • Page 26: Act Operation

    CD-ROM of calibration tool software to run on your personal computer. (CD supplied with ACT kit.) Hardware Set-up To connect your PC to the APECS 4500 unit a standard RS-232 nine-pin cable and a proprietary interface module is required. Both are included in the ACT kit. NOTE Make sure power to the PC and the APECS unit is off when making connections.

  • Page 27: Software Set-Up

    The set-up is now complete and you are ready to run ACT. • To run the ACT software, please refer to “Running the ACT Software” below. • Put the original CD-ROM in a safe place in case the files on your hard drive are damaged or lost. Woodward...

  • Page 28: Basic Act Operation

    3. If no icon exists, click on the Start button, highlight “Programs,” find the ACT software and click to start it. Default is Woodward, then select “APECS-EPS Calibration Tool.” 4. Make sure the COM port designation in ACT matches the serial port on the back of your PC.

  • Page 29: Act Menus & Options

    The following commands are available under the File Menu. • Save APECS Cal to File • View Cal File Comments • View Text File • Convert APECS Cal to Text • Convert Cal File to Text • Convert Cal File to Strategy Woodward...

  • Page 30: Save Apecs Cal To File

    <Enter> or click Save Edit. You can re-edit comments by clicking them, changing the text on the top line and clicking Save Edit. Comments can be deleted by clicking on them and then clicking “Delete” or by pressing <Del>. Woodward...

  • Page 31: View Cal File Comments

    This command is a convenient way to view text files. 1. Choose File View Text File. 2. ACT will prompt for a text file to view. 3. Select a file and click OK. 4. ACT will open the selected file with the default viewer for that file type. Woodward...

  • Page 32: Convert Commands

    This command is used to convert old ACT files for use with controllers that have a different control strategy version. ACT will: 1. Parse through all of the calibration parameters in the old ACT file. 2. Search for the same calibration parameters in the new ACT file and assign values from the old calibration. Woodward...

  • Page 33: Calibrate Menu

    The “Change APECS Calibration” command allows you to calibrate (configure and adjust) various parameters associated with the APECS controller. APECS 4500 is a programmable engine governor. Changing APECS calibration parameters is the means to configure the APECS controller for specific engines, applications and environments, and for adjusting PID gains.

  • Page 34: Download Cal File To Apecs

    Download Cal File to APECS. The following screen allows you to select a Cal file to download. 2. Choose a file and click OK. The following screen will show the progress. 3. The following screen is shown when the operation is complete. Woodward...

  • Page 35: Compare Apecs Cal To File Cal

    APECS unit. The feature is useful, for example, to ensure that the saved file matches the calibration in the APECS unit. To Compare APECS Cal to File Cal: 1. Choose File Compare APECS Cal to File Cal. This screen allows you to select a Cal File to compare. Woodward...

  • Page 36: Change Apecs Password

    The option is useful, for example, to prevent unauthorized changes to a known good calibration set in the APECS unit. By default, the APECS unit is not password protected. To Change APECS Password: 1. Choose Calibrate Change APECS Password. You will be prompted for the current password. Woodward...
  • Page 37 APECS password to “peg,” which is the default password. ACT Operation with the New Password: Once a password is added or changed, the following calibration features become password protected: Change APECS Calibration Download Cal File to APECS Change APECS Password APECS Calibration Wizard Woodward...

  • Page 38: Apecs Calibration Wizard

    Monitor Menu The Monitor Menu allows you to observe engine and APECS operation in real time. The following commands are available under the Monitor Menu. • Parameter View • Parameter Plot • Display Faults • Control Strategy • Parameter List Woodward...

  • Page 39: Parameter View

    This value will be adjusted when the graph is resized. This also applies to the print functionality for this screen. All of the data will be recorded in a revolving buffer for use by the “Save to File” feature (see below). Woodward...
  • Page 40 Controls how much data is displayed on the X axis. This value may automatically adjust for screen resolution. X Axis Sample Rate Controls how often the data from the controller is used to update the screen. Data received between timer ticks is discarded. Woodward...

  • Page 41: Display Faults

    To Display the Parameter List: 1. Choose Monitor > Parameter List from the main menu. 2. The F5/F6 keys will backup/advance through the list. Press F9 or click on “On View List” to toggle the selected parameter on the Parameter View screen. Woodward...
  • Page 42 Several parameter view screens can be open with different configurations by changing the configuration on the parameter list screen (F9 or Open), then opening a new Parameter View. NOTE: Only one of the parameter view screens can be monitoring the controller at once. Woodward...

  • Page 43: Configure Menu

    An error message will be displayed AFTER you click OK if a controller cannot be found or if the port cannot be opened. COM ports outside of this range can be used by editing the default COM port registry key for this application. Woodward...

  • Page 44: Help Menu

    User’s Manual This command accesses the User’s Manual, which includes comprehensive information on the APECS 4500 controller, wiring diagrams, ACT software menus, and calibration parameters. The manual may be viewed online or printed for future reference. Woodward...

  • Page 45: Chapter 4. Calibrating Apecs Features

    APECS All-purpose Calibration Tool (ACT). Safety Precautions The APECS 4500 is a user configurable engine speed governor and will follow your settings and commands immediately. Please be aware of this when calibrating and entering values in the unit.

  • Page 46: Calibrating An Apecs Unit

    4500 Electronic Engine Speed Governing System Manual SE-4097 Calibrating an APECS Unit Once the system set-up is complete it is fairly easy to calibrate an APECS 4500 controller. Before proceeding with calibration, please ensure that the controller unit is connected to the COM port and powered.

  • Page 47: Calibrating An Apecs Unit With A Saved Calibration File

    3. ACT will download file calibration to APECS permanent memory. 4. Repeat Steps 1 and 2 if multiple APECS units are to be calibrated. NOTE: The APECS unit must be powered up, but need not be mounted on the engine to carry out the calibration procedure. Woodward...

  • Page 48: Understanding Apecs Calibration Parameters

    Why do we need to calibrate the APECS system? APECS 4500 is a software programmable system and has no manual adjustment. Calibrating is the only means of configuring and adjusting the controller for your specific application.

  • Page 49: List Of Parameters

    Coil Ignition = 2 SPEED_TYPE Magneto = 3 Speed Hall Effect = 131 Input Configuration No. of pulses per PULSES_PER_REV engine revolution No. of pulses until PULSES_PER_UPDATE next engine speed update Engine Start Time autocrank Calibration AUTOCRANK_CRANK_TIME holds crank solenoid on (sec) Woodward...
  • Page 50 2: critical shutdown AUXILIARY_OUTPUT_MODE 3: PTO 4: autocrank Actuator 5: mimic LED 6: Output glowplug Calibration 0: no output 1: use RPM 2: critical shutdown AUXILIARY_OUTPUT_2_MODE 3: PTO 4: autocrank 5: mimic LED 6: glowplug DROOP_PERCENT HIGH_ACTFDBK_LMX Actuator current limit Woodward...

  • Page 51: Calibration Procedures: Pid Gains Adjustment

    Figures 16–20 illustrate less desirable conditions often encountered while tuning an application and suggest probable causes. Figure 21 shows a plot of a properly tuned application. Although conditions may vary according to application and nature of load, this plot is typical of what is often desired. Woodward...

  • Page 52: Engine Set Speed Calibration Parameters

    If it is not possible to stabilize engine performance, check smoothness of the linkage. Engine Set Speed Calibration Parameters Calibration Procedures The APECS 4500 has two primary means of selecting engine speed setpoint: • Using analog speed setpoint ( EXTERNAL_ANALOG_MODE •...
  • Page 53 Also used to specify the maximum rpm commanded with an analog input. SET_SPEED_MIN Lowest engine speed command possible when using variable speed mode to ramp engine speed down (rpm). = 5). (SWITCH_CONFIGURATION Also used to specify the minimum rpm commanded with an analog input. Woodward...

  • Page 54: External Analog Input Calibration (With Ivs)

    External Analog Input Calibration (with IVS) Use the external analog input for a variety of functions such as (1) Pedal position sensor with idle verification switch, (2) Remote speed adjustments, and (3) Trim potentiometer. See “Auxiliary Output Wiring” for wiring analog inputs. Woodward...
  • Page 55 BRAKE_DELAY seconds. Otherwise, similar to Mode 013. APS calibration mode. See Allows an external pot from various applications to “External Pot Calibration” interface properly with the controller. (*) Reverse pot option reverses speed increase/decrease relationship to a clockwise rotation of pot. Woodward...

  • Page 56: Switch Configuration Modes

    WARMUP_TIME seconds, after which the engine speed either increases at RAMP_UP_RATE or decreases at RAMP_DOWN_RATE to the speed selected by the rotary switch (SET_SPEED_1 to SET_SPEED_3). When another speed is selected with the switch, the commanded engine speed is ramped to the new set speed. Woodward...

  • Page 57: External Pot Calibration

    SET_SPEED_MIN. External Pot Calibration This feature allows an external pot from a variety of applications to interface properly with the APECS 4500. Refer to Table 4 for mode configurations and descriptions. Calibration Parameters Needing Configuration: EXTERNAL_ANALOG_MODE Allows the external analog input to be configured in a variety of ways.

  • Page 58: Pto Input

    SET_SPEED_WARMUP. Even if WARMUP_TIME is set to 0, this will be the initial engine speed command. It does not change until the engine is running and the toggle switch is pressed. The toggle switch has no effect when the engine is not running. Woodward...

  • Page 59: Speed Input Configuration Parameters

    The number of pulses received by the controller between engine speed calculations and updates. The fewer the pulses, the faster the update rate and the lower the resolution; the greater the pulses, the greater the averaging effect on calculated engine speed. Factory set to zero. Must be non-zero to operate. Woodward...

  • Page 60: Pulses_Per_Rev Faq

    Magnetic Pickup Input or Hall Effect Sensor Pulses per revolution = number of teeth on the flywheel ® Woodward Mini-Gen Signal Generator Pulses per revolution = 0.5 x drive ratio if Mini-Gen is driven at other than crankshaft speed...

  • Page 61: Engine Start Calibration Parameters

    4500 is to be configured. Set to a value of 6 for glowplug control. See “Auxiliary Outputs” for settings. AUXILIARY_OUTPUT_2_MODE This parameter is used to let the software know how auxiliary output #2 of APECS 4500 is to be configured. Set to a value of 6 for glowplug control. See “Auxiliary Outputs” for settings.

  • Page 62: Engine Cranking

    This parameter is used to let the software know how the auxiliary output of APECS 4500 is to be configured. See “Auxiliary Outputs” for settings. AUXILIARY_OUTPUT_2_MODE This parameter is used to let the software know how auxiliary output #2 of APECS 4500 is to be configured. See “Auxiliary Outputs” for settings. Calibration Procedures...

  • Page 63: Diagnostics Calibration Parameters

    The time, in seconds, that the engine must be running before the engine protection logic begins to monitor the engine protection input. This permits the APECS 4500 to automatically account for oil pressure switches and similar devices that indicate a fault condition when the engine is not running. Setting to 8000 or more will disable the engine protection option.

  • Page 64: Overspeed / Underspeed Protection

    LED. This signifies to the user that the engine stopped due to overspeed or underspeed engine conditions. The engine may later be restarted without resetting the unit; this action will cause the fault code to reset and the LED will then stop flashing. Woodward...

  • Page 65: Overspeed Faq

    4500 Electronic Engine Speed Governing System Overspeed FAQ How Does Overspeed Work? The APECS 4500 has the diagnostic capability to detect and react to an overspeed condition. The feature uses two programmable parameters, OVERSPEED_RPM . Overspeed feature immediately shuts off the actuator when the...
  • Page 66 Once the duty cycle limit ramps up completely, current protection is fully recovered. The lamp on the APECS controller flashes (flash code 9) to indicate controller is limiting excessive actuator current. Woodward...
  • Page 67 For most applications, the default value for the hard limit will suffice to protect the controller. If desired, may be decreased. Increasing this parameter HIGH_AFB_CRITICAL may jeopardize the control module and is not recommended. Woodward...

  • Page 68: Auxiliary Outputs

    This parameter is used to let the software know how the auxiliary output of APECS 4500 is to be configured. AUXILIARY_OUTPUT_2_MODE This parameter is used to let the software know how auxiliary output #2 of APECS 4500 is to be configured. Calibration Procedures...

  • Page 69: Droop Governing

    Monitor actuator feedback at no load and at full load and set DROOP_ACTFDBK_MIN to these values respectively. Set DROOP_ACTFDBK_MAX DROOP_PERCENT desired droop up to 15%. Load is inferred by measuring the actuator sense current output of the current driver. to zero for isochronous governing. DROOP_PERCENT Woodward...

  • Page 70: Calibration Setup & Configuration Parameters Flowchart

    APECS operation can begin The APECS 4500 is a user configurable engine speed governor and will follow your settings and commands immediately. It is possible to enter values in the APECS module that are in excess of what the engine is capable of performing and outside of safe operating range.
  • Page 71 Auxiliary Output #2 Drive-by-wire AUXILIARY_OUTPUT_2_MODE Similar to set speed with pot but with AUXILIARY_OUTPUT_2_RPM additional fault management. Suitable for pedal applications. PTO is available Idle verification switch is available Droop Governing Default DROOP_CURRENT_MAX DROOP_CURRENT_MIN DROOP_PERCENT PTO Input EXTERNAL_ANALOG_MODE SWITCH_CONFIGURATION Woodward...
  • Page 72 Drive-by-wire, no IVS (EXTERNAL_ANALOG_MODE =003) SET_SPEED_MAX Drive-by-wire, IVS normally closed (EXTERNAL_ANALOG_MODE =103) SET_SPEED_MAX Drive-by-wire, IVS normally open (EXTERNAL_ANALOG_MODE =203) Drive-by-wire, no IVS (EXTERNAL_ANALOG_MODE =013) SWITCH_CONFIGURATION 1-4 Drive-by-wire, IVS normally closed (EXTERNAL_ANALOG_MODE =113) SET_SPEED 1-4 Drive-by-wire, IVS normally open (EXTERNAL_ANALOG_MODE SET_SPEED_MIN =213) SET_SPEED_MAX Woodward...
  • Page 73 Set EXTERNAL_ANALOG_MODE back to the desired speed mode when finished. PID Gains too low Derivative gain too high SET_SPEED_WARMUP WARMUP_TIME RAMP_DOWN_RATE RAMP_UP_RATE SPEED_DECREASE_DELAY (PTO only) Integral gain too low Desired response Woodward...

  • Page 74: Chapter 5. Troubleshooting

    7. Try adjusting the gains to achieve stability. Fault Codes The APECS 4500 controller is capable of identifying certain fault conditions and alerting the user to them. A flashing LED indicates the fault conditions. The current fault code list is shown in Table 6. Please note the following: 1.
  • Page 75 Auxiliary output Check the lamp or relay hooked to the output. If #2 is shorted fault is still present, consult factory. Actuator Check actuator wiring and actuator resistance. disconnected Resistance should be less than 10 ohms. or open circuit Woodward...

  • Page 76: Glossary Of Technical Terms

    Device that converts an electrical signal from the APECS controller to an output shaft position APECS (Advanced Proportional Engine Control System) Engine governing system developed by Woodward Analog Pedal Position. An analog input with voltage proportional to the desired engine speed...

  • Page 77: Chapter 6. Service Options

    If the core (field unit) is returned to Woodward within 60 days, Woodward will issue a credit for the core charge. [The core charge is the average difference between the flat rate replacement/exchange charge and the current list price of a new unit.]...

  • Page 78: Flat Rate Repair

    01-1205). This option is applicable to mechanical products only. Returning Equipment for Repair If a control (or any part of an electronic control) is to be returned to Woodward for repair, please contact Woodward in advance to obtain a Return Authorization Number.

  • Page 79: Return Authorization Number

    +1 (970) 482-5811]. They will help expedite the processing of your order through our distributors or local service facility. To expedite the repair process, contact Woodward in advance to obtain a Return Authorization Number, and arrange for issue of a purchase order for the item(s) to be repaired.

  • Page 80: Engineering Services

    4500 Electronic Engine Speed Governing System Manual SE-4097 Engineering Services Woodward Industrial Controls Engineering Services offers the following after-sales support for Woodward products. For these services, you can contact us by telephone, by email, or through the Woodward website. • Technical Support •...

  • Page 81: Technical Assistance

    Type of Fuel (gas, gaseous, steam, etc) Rating Application Control/Governor Information Please list all Woodward governors, actuators, and electronic controls in your system: Woodward Part Number and Revision Letter Control Description or Governor Type Serial Number Woodward Part Number and Revision Letter...
  • Page 82 BS EN ISO 9001:1994 6 March 2001 Woodward has company-owned plants, subsidiaries, and branches, as well as authorized distributors and other authorized service and sales facilities throughout the world. Complete address / phone / fax / email information for all locations is available on our website.

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