Woodward DSS-2 User Manual
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Woodward DSS-2 User Manual

Two-channel digital speed switch
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DSS-2
Two-Channel
Digital Speed Switch
Manual 36598

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  • Page 1 User Manual DSS-2 Two-Channel Digital Speed Switch Manual 36598...
  • Page 2 Revisions—Text changes are indicated by a black line alongside the text. 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

    Manual 36598 DSS-2 Two-Channel Digital Speed Switch Contents ..............EGULATORY OMPLIANCE ..........LECTROSTATIC ISCHARGE WARENESS 1. G ............1 HAPTER ENERAL NFORMATION Introduction ......................1 How Speed Switches Work ..................2 Set vs. Reset....................2 Normal vs. Reverse Relay Logic..............2 Autocrank......................3 Glow Plug Preheat ..................3 System Components ....................3...
  • Page 4 Calibrate Menu......................33 Change DSS-2 Calibration................33 Calibration Categories ..................35 List of Parameters..................36 Download Cal File to DSS-2 .................39 Compare DSS-2 Cal to File Cal ..............40 Change DSS-2 Password ................41 DSS-2 Calibration Wizard ................43 Monitor Menu ......................44 Parameter View ....................44 Parameter Plot ....................45 Display Faults....................46...

  • Page 5: Regulatory Compliance

    Power cabling is limited to less than 10m (32.8’) in total length. See wiring diagrams for specific cable types required. Declaration of Conformity The official Declaration of Conformity is available upon request. Please see the “How to Contact Woodward” section in Chapter 7 to request a copy. 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

    Three indicator lamps permit system monitoring and diagnosis without use of additional tools. As shipped from the factory, DSS-2 can be manually adjusted on most applications that supply a MPU frequency of 2500 to 5000 Hz. Optionally, the user may attach...

  • Page 8: How Speed Switches Work

    Reverse mode such that the relay is energized in the Reset condition and de- energized in the Set condition. This is helpful in applications such as engine crank disable where a loss of power to the DSS-2 should produce the same response as Woodward...

  • Page 9: Autocrank

    Rest Time and Maximum number of crank attempts are user selectable using the ACT. The rpm at which the DSS-2 assumes the engine has started, referred to as the crank disable speed, is adjustable using the multi-turn potentiometer for that channel.
  • Page 10 Shielded wiring is recommended for the MPU. The DSS-2 is equipped with three LEDs: one green and two red. All LEDs will be turned on for one second following power up as a lamp test and as an indication of normal operation.

  • Page 11: All-Purpose Calibration Tool (Act)

    ACT is a PC (personal computer) based software calibration and monitoring tool. ACT is designed specifically for use with engines equipped with the DSS-2 controller. The tool can be run on any IBM compatible computer that meets the requirements listed ACT Installation”...

  • Page 12: Chapter 2. Specifications

    NOTE The scope of this manual does not include selection of speed sensors or other components that Woodward offers for use with the DSS-2 system. Information is available on our website at www.woodward.com. NOTE The need for sub-components such as switches is application dependent.

  • Page 13: Chapter 3. Installation

    Power Leads: Power leads are to be connected directly to a switched power source (i.e., battery). With both channels on, DSS-2 draws a maximum of 100 mA. Use of a slow-blow fuse is recommended in the battery (positive) wire. Electrical loads attached to the two relays should be separately fused.
  • Page 14 1 mA each). The external switches should be selected for prolonged use at these low currents. One side of the switch should be connected to battery voltage and the other side connected to the DSS-2 switch input. Figure 2. DSS-2 Dimensions...
  • Page 15 Manual 36598 DSS-2 Two-Channel Digital Speed Switch Table 1. Controller Wiring FUNCTION PIN INFORMATION BAT(+), GND(-) Battery RPM(+), RPM(-) MPU Speed Signal Input Channel 1 C-1, NC-1, NO-1 C-2, NC-2, NO-2 Channel 2 Verify/Start Switch Reset Switch Engine Protection Switch...

  • Page 16: Controller Pinout

    DSS-2 Two-Channel Digital Speed Switch Manual 36598 Controller Pinout Use the diagram below to connect your DSS-2 controller to battery power, the mag pickup, loads, switches and ACT. NOTE All cabling for the DSS-2 controller is limited to less than 3m (9.84’).

  • Page 17: Speed Sensor Installation

    The shield should be grounded at the controller only. DSS-2 requires a minimum output voltage of 2 Vac. It is recommended that the MPU output not be shared with other devices (tachometers, etc.).

  • Page 18: Chapter 4. Calibration

    Calibration with ACT ACT (All-purpose Calibration Tool) can be used to provide a wide variety of custom features to the DSS-2. Refer to Chapter 5 for general information regarding installation, connection and operation of ACT. The Calibration Wizard is the preferred approach to ACT calibration, but similar results can be obtained using the Calibrate/Change DSS-2 Calibration Menu item (see Chapter 5 for details).
  • Page 19 Please be aware of this when calibrating and entering values in the unit. It is possible to enter values in the DSS-2 unit that are in excess of what the engine is capable of performing and outside of safe operating range.

  • Page 20: Speed Switch Configuration

    DSS-2 Two-Channel Digital Speed Switch Manual 36598 Speed Switch Configuration As shipped from the factory, DSS-2 is configured as follows: • Two-channel speed switch • Normal operation • Automatic reset at 80% of setspeed • Range of pot adjustable set speed: 2500 to 5000 Hz •...

  • Page 21: Manual Calibration

    4. Adjust speed setpoints until desired set speeds are achieved. Red LEDs should illuminate when set speeds are reached. 5. Install DSS-2 on engine and confirm MPU input with engine running. Confirm speed switch operation. If concerned about overspeeding the engine or load, attach 12 volts to the verify (VER) input.

  • Page 22: Normal Operation Vs. Reverse Operation

    Manual Reset: The speed switch will return to the “Reset”state when the speed falls below the setspeed AND the RST switch input is connected to battery voltage Latched Reset: The speed switch will remain in the “”Set” state until the DSS-2 module is powered down then powered back up.

  • Page 23: Speed Switch Options

    Manual 36598 DSS-2 Two-Channel Digital Speed Switch Speed Switch Options Potentiometer Control Range: Set Speed Min and Set Speed Max specify the range of engine speeds (frequencies) controllable with the set speed potentiometer. Values of 10-8000 are acceptable. The narrower the range, the finer the resolution on adjustment.

  • Page 24: Autocrank Configuration

    Reset Speed = Set Speed * Reset Percentage Autocrank Configuration As shipped from the factory, both DSS-2 channels are configured as speed switches. The ACT is required to enable Autocrank operation. Once enabled, the Crank Disconnect rpm can be manually adjusted using the potentiometer.

  • Page 25: Manual Calibration

    Manual 36598 DSS-2 Two-Channel Digital Speed Switch A typical autocrank installation is shown below. In this installation, Channel 1 is configured as an overspeed shutdown switch that will interrupt power to the ignition coil when an overspeed threshold is exceeded. Channel 2 is configured as an autocrank controller that will energize the starter motor when the Start Switch is turned on.

  • Page 26: Autocrank Calibration Using Act

    Autocrank Calibration Using ACT ACT can be used to customize the Autocrank feature in DSS-2. Refer to Chapter 5 for general information regarding installation, connection and operation of ACT. The Calibration Wizard is the preferred approach to ACT calibration, but similar results can be obtained using the Calibrate/Change DSS-2 Calibration Menu item.

  • Page 27: Autocrank Options

    EP switch input. Glow Plug Controller Configuration As shipped from the factory, both DSS-2 channels are configured as speed switches. The ACT is required to enable glow plug controller operation. The other channel must be configured for Autocrank operation. Once enabled, the Glow Plug Preheat time can be manually adjusted using the potentiometer.

  • Page 28: Manual Calibration

    DSS-2 Two-Channel Digital Speed Switch Manual 36598 A typical glow plug installation is shown below. In this installation, Channel 1 is configured as an autocrank controller that will energize the starter motor when the Start Switch is turned on and after the glow plug pre-heat sequence is complete.

  • Page 29: Glow Plug Controller Adjustment Using Act

    GLOW PLUG_TIME. Glow Plug Controller Adjustment Using ACT ACT can be used to customize the range of glow plug pre-heat times in the DSS-2. Refer to Chapter 5 for general information regarding installation, connection and operation of ACT.

  • Page 30: Pre-Heat Time

    Engine Protection Switch Configuration ACT can be used to configure the Engine Protection (EP) input to the DSS-2. Refer to Chapter 5 for general information regarding installation, connection and operation of ACT. The Calibration Wizard is the preferred approach to ACT calibration, but similar results can be obtained using the Calibrate/Change DSS-2 Calibration Menu item.

  • Page 31: Completing Wizard Configuration

    Manual 36598 DSS-2 Two-Channel Digital Speed Switch To Ignore EP input for a brief period after starting: Set Run Time (sec) to a non- zero value. To ignore intermittent switch contact closures: To provide some basic switch contact debounce, set Debounce Time (msec) to a non-zero value.

  • Page 32: Act Operation

    (CD supplied with ACT kit.) Hardware Set-up To connect your PC to the DSS-2 use the cable provided with the calibration tool kit. This cable has a DB-9 connector on one end and a four-pin white plastic Molex connector on the other end. Please note that the DSS-2 serial communication port is for service and programming only;...

  • Page 33: Software Set-Up

    Manual 36598 DSS-2 Two-Channel Digital Speed Switch Figure 7. ACT System Set-Up Software Set-Up ACT software can be automatically installed on your hard drive from the CD-ROM supplied with the kit. To install the software, follow the procedures below. NOTE Close all applications to prevent possible conflict between the ACT installer and other programs.

  • Page 34: 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 35: Moving Around The Software

    Convert DSS-2 Cal to Text Convert Cal File to Text Convert Cal File to Strategy Change DSS-2 Calibration Download Cal File to DSS-2 Compare DSS-2 Cal to File Cal CALIBRATE MENU Change DSS-2 Password DSS-2 Calibration Wizard Parameter View Parameter Plot...

  • Page 36: File Menu

    Convert Cal File to Strategy Save DSS-2 Cal to File This command allows you to save DSS-2 calibration data to a designated file. The ACT uploads the calibration set from the DSS-2 controller and saves it to a computer file. This operation is usually done after the controller has been calibrated for satisfactory engine performance but can also be done at any other time.

  • Page 37: View Cal File Comments

    .ACT file that cannot be viewed or printed directly. Viewing and printing must be done from a converted text file. See “Convert DSS-2 Cal to Text” and “Convert Cal File to Text” commands. View Cal File Comments...

  • Page 38: View Text File

    You may use the View Text File command to view text files. Convert DSS-2 Cal to Text This command allows you to create a text file of DSS-2 calibration data for viewing or printing from any text editor utility in Windows. A printed copy of the calibration data can be useful for future reference.

  • Page 39: Convert Cal File To Text

    Calibrate Menu The Calibrate Menu allows you to perform operations related to DSS-2 calibration. The following commands are available: • Change DSS-2 Calibration* •...
  • Page 40 A complete list of parameters appears in the following pages. All adjustments are stored immediately in non-volatile memory in the DSS-2 unit. The DSS-2 controller will retain the changes even if power is lost or the ACT is disconnected. To Change DSS-2 Calibration Parameters: 1.

  • Page 41: Calibration Categories

    Manual 36598 DSS-2 Two-Channel Digital Speed Switch Calibration Categories To incorporate any of the programmable features in your system, a set of parameters associated with each feature must be calibrated using the calibration tool (ACT). These parameters are grouped under various categories under the Calibrate Menu in ACT.

  • Page 42: List Of Parameters

    DSS-2 Two-Channel Digital Speed Switch Manual 36598 List of Parameters The parameter list provides information regarding each of the parameters that can be adjusted when a computer is connected to the controller via the COM port and the ACT software. The COM port and ACT are intended only for configuration and periodic service.
  • Page 43 Manual 36598 DSS-2 Two-Channel Digital Speed Switch Parameter List (Cont’d.) FACTORY CATEGORY PARAMETER DESCRIPTION Configuration bits, Channel 2. Bit 7: 1= Overspeed Fault Enable Bit 5: 1 = Sequence bit – Ch 1 after Ch 1 CHNL_2_CONFIG 000000001B Bit 4: 1 = Go to set on Loss of...
  • Page 44 DSS-2 Two-Channel Digital Speed Switch Manual 36598 Parameter List (Cont’d.) FACTORY CATEGORY PARAMETER DESCRIPTION Minimum rpm to enable engine EP_ENABLE_RPM protection switch Minimum time above EP_RUN_TIME EP_ENABLE_RPM to enable 0 sec engine protection switch Minimum engine protection switch EP_TIME 50 msec...

  • Page 45: Download Cal File To Dss-2

    DSS-2 Two-Channel Digital Speed Switch Download Cal File to DSS-2 The “Download Cal File to DSS-2” command allows you to download the entire calibration set from a file to the DSS-2 permanent memory. This is a convenient one-step method for: •...

  • Page 46: Compare Dss-2 Cal To File Cal

    Compare DSS-2 Cal to File Cal This command lets you check the differences in calibration sets between a saved file and the DSS-2 unit. The feature is useful, for example, to ensure that the saved file matches the calibration in the DSS-2 unit.

  • Page 47: Change Dss-2 Password

    This command allows you to add or change a password to protect certain calibration features. The option is useful, for example, to prevent unauthorized changes to a known good calibration set in the DSS-2 unit. By default, the DSS-2 unit is not password protected.
  • Page 48 Passwords are upper and lower case sensitive. After changing your password, please record it in a safe place for future reference. To revert to no password protection, change DSS-2 password to “peg,” which is the default password. ACT Operation with the New Password:...

  • Page 49: Dss-2 Calibration Wizard

    DSS-2 Two-Channel Digital Speed Switch DSS-2 Calibration Wizard The DSS-2 Calibration Wizard is an interactive guide to help you get your controller unit up and running as quickly as possible. To Calibrate a Controller Unit Using the DSS-2 Calibration Wizard: 1.

  • Page 50: Monitor Menu

    DSS-2 Two-Channel Digital Speed Switch Manual 36598 Monitor Menu The Monitor Menu allows you to observe engine and DSS-2 operation in real time. The following commands are available under the Monitor Menu. • Parameter View • Parameter Plot • Display Faults •...

  • Page 51: Parameter Plot

    Manual 36598 DSS-2 Two-Channel Digital Speed Switch Parameter Plot The Parameter Plot command lets you view engine performance on screen in the form of a real-time graph. This feature allows you to perturb the system and observe response to fine tune engine performance.

  • Page 52: Display Faults

    DSS-2 Two-Channel Digital Speed Switch Manual 36598 Plot 1 / Plot 2 Use the pull-down to select the desired parameter to plot. Axis Min / Max Enter the minimum / maximum value for the parameter value. X Axis Time Scale Controls how much data is displayed on the X axis.

  • Page 53: Control Strategy

    Manual 36598 DSS-2 Two-Channel Digital Speed Switch screen. The text on the button will change to “Start” and clicking it again will re-start the automatic updating. NOTE If any other screen requests data from the controller while this screen is updating, this screen will automatically pause.

  • Page 54: Configure Menu

    Configure Menu Configure Serial Port This command allows you to designate the proper COM port for your PC to enable communication between the ACT and the DSS-2 controller. To Configure the Serial Port: 1. From the main menu screen, choose Configure Custom Serial Port.

  • Page 55: Help Menu

    User Manuals This command accesses the User Manual, which includes comprehensive information on the DSS-2 controller, wiring diagrams, ACT software menus, and calibration parameters. The manual may be viewed online or printed for future reference. Woodward...

  • Page 56: Chapter 6. Troubleshooting

    3. Confirm that the channel LEDs transition at the appropriate frequencies. 4. With the loads disconnected from DSS-2, use an ohmmeter to confirm that relays are working as expected. With no power to the relay, there should be continuity between the C and NC contacts and no continuity between C and NO contacts.
  • Page 57 Manual 36598 DSS-2 Two-Channel Digital Speed Switch Table Fault Codes FLASH RESPONSE CAUSE FAULT CODE Engine rpm has exceeded Channel 1 Channel 1 Set Condition speed setpoint and Overspeed CHNL_1_CONFIG.7 = 1. Engine rpm has exceeded Channel 2 Channel 2...

  • Page 58: Glossary Of Technical Terms

    Glossary of Technical Terms ACT (All-purpose Calibration Tool) Software PC software program for configuring and calibrating the DSS-2 controller Actuator Device that converts an electrical signal from the DSS-2 controller to an output shaft position Cal File File containing DSS-2 calibration data...

  • Page 59: Chapter 7. Service Options

    Product Service Options The following factory options are available for servicing Woodward equipment, based on the standard Woodward Product and Service Warranty (5-01-1205) that is in effect at the time the product is purchased from Woodward or the service is performed: •...

  • Page 60: Returning Equipment For Repair

    Warranty 5-01-1205). This option is applicable to mechanical products only. Returning Equipment for Repair If a control (or any part of an electronic control) is to be returned to Woodward for repair, please contact Woodward in advance to obtain a Return Authorization Number.

  • Page 61: Replacement Parts

    Fax—+1 (970) 498-3058 For assistance outside North America, call one of the following international Woodward facilities to obtain the address and phone number of the facility nearest your location where you will be able to get information and service. Facility...

  • Page 62: Engineering Services

    The field engineers are experienced both on Woodward products as well as on much of the non-Woodward equipment with which our products interface. For field service engineering assistance, please contact us via telephone, email us, or use our website and reference Customer Services and then Technical Support.

  • Page 63: 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 64 Phone +1 (970) 482-5811 • Fax +1 (970) 498-3058 Email and Website—www.woodward.com 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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