Professional Documents
Culture Documents
ISSUE: 5
TEXCEL CONFIGURATION
&
CALIBRATION GUIDE.
INTRODUCTION
IM 1347/1 ISSUE 5
Table of Contents
TABLE OF CONTENTS............................................................................................. 1
TABLE OF FIGURES ................................................................................................ 6
RECORD OF AMENDMENTS ................................................................................... 8
1
INTRODUCTION .................................................................................................. 9
1.1
1.2
2.1
2.2
2.3
2.4
3.1
Configure Analogue Channels ............................................................................................................... 13
3.1.1
Initial Configuration Or Utilising A Spare Channel ......................................................................... 14
3.1.2
Software settings for platinum resistance thermometers................................................................... 15
3.1.3
Software specific settings for thermocouples. .................................................................................. 16
3.1.4
Completing the Initial Channel Configuration.................................................................................. 16
3.1.5
Setting Alarm Related Parameters .................................................................................................... 17
3.1.6
Setting Log Related Parameters ........................................................................................................ 17
3.1.7
Sorting log data ................................................................................................................................. 18
3.1.8
Calculations ...................................................................................................................................... 18
3.1.9
Calculation syntax ............................................................................................................................ 19
3.1.10
Variables ........................................................................................................................................... 19
3.1.11
Simple Operators .............................................................................................................................. 20
3.1.12
Logical operators .............................................................................................................................. 20
3.1.13
Math Functions ................................................................................................................................. 21
3.1.14
Digital Output Control Via Calculation ............................................................................................ 21
3.1.15
Further Calculation Examples .......................................................................................................... 21
3.1.16
Triggering Calculations From Set-point Logger ............................................................................... 25
3.2
Calibrate Analogue Inputs ..................................................................................................................... 25
3.2.1
Basic Calibration Method ................................................................................................................. 26
3.2.2
Aborting A Calibration. .................................................................................................................... 27
3.2.3
Changes That Require Channel Re-Calibration ................................................................................ 27
3.2.4
Changes That Do Not Require Channel Re-Calibration ................................................................... 28
3.2.5
Problems With Calibration ............................................................................................................... 28
June 2009
TEXCEL SOFTWARE
3.2.6
3.2.7
3.2.8
3.2.9
3.2.10
3.2.11
3.2.12
3.2.13
3.2.14
3.2.15
3.2.16
3.2.17
3.2.18
3.2.19
INTRODUCTION
Calibration Error ADC is saturated - the input level cannot be determined accurately. ................ 28
Calibration Error ADC is grounded - the input level cannot be determined accurately. ................ 29
Calibration The ADC Input is too close to a previous point. ......................................................... 29
Calibration Calibration for this channel has expired. ..................................................................... 29
Diagnosing Faults On Analogue Input Channels .............................................................................. 29
Calibration Examples ........................................................................................................................ 31
Dynamometer torque calibration (all dynamometers except AC range). .......................................... 31
Cold Junction Reference Calibration (non Texcel V12 Systems)..................................................... 33
Cold Junction Reference Calibration (Texcel V12 Systems)............................................................ 34
Thermocouple Inputs ........................................................................................................................ 34
Thermocouple Calibration (Millivolt Method) ................................................................................. 35
Thermocouple Calibration (Compensated Method).......................................................................... 36
Pressure/Linear Calibration .............................................................................................................. 36
The Calibration Report. .................................................................................................................... 37
3.3
Calibrate Analogue Outputs .................................................................................................................. 38
3.3.1
Analogue Output Calibration Procedure ........................................................................................... 40
3.3.2
Analogue Output Calibration Examples ........................................................................................... 42
3.3.3
Example 1: Water Control Output (E to P converter). ...................................................................... 42
3.4
Throttle and Dyno Setup for In-Cell Power Module Box - E320108B ............................................... 43
3.4.1
Electronic Calibration of the Throttle Actuator ................................................................................ 43
3.4.2
Mechanical Set-up of the Throttle Actuator ..................................................................................... 47
3.4.3
Calibrating Dynamometer Demand for an Eddy Current Dynamometer.......................................... 50
3.5
Throttle and Dyno Setup for In-Cell Power Module Box - E320175A ............................................... 51
3.5.1
Calibration of the Throttle Actuator ................................................................................................. 51
3.5.2
Checking the Min and Max Position ................................................................................................ 54
3.5.3
Checking the Throttle Control from the Manual Desktop Controller ............................................... 54
3.5.4
Calibrating Dynamometer Demand for an Eddy Current Dynamometer.......................................... 54
3.5.5
Checking the Throttle Calibration .................................................................................................... 55
3.6
Configure Digital Channels.................................................................................................................... 57
3.6.1
Digital Input Configuration .............................................................................................................. 57
3.6.2
Digital Output Configuration ............................................................................................................ 58
3.7
Configure External Controllers ............................................................................................................. 58
3.7.1
Example 1: Control of Engine Cooling Air Speed. .......................................................................... 59
3.7.2
Example 2: Engine Coolant Temperature Control. ........................................................................... 59
3.7.3
Theory of operation .......................................................................................................................... 59
3.7.4
External Controller Configuration .................................................................................................... 60
3.7.5
Starting the external controller configuration dialog ........................................................................ 60
3.7.6
Setting up the controller actuator output ........................................................................................... 62
3.7.7
Setting up the controller inputs ......................................................................................................... 62
3.7.8
Setting the controller coefficients ..................................................................................................... 62
3.7.9
Special Applications for External Controllers .................................................................................. 65
3.7.10
Potential Problems With External Controllers .................................................................................. 65
3.7.11
Servo Output Fluctuation .................................................................................................................. 65
3.7.12
Output Driven in Reverse Direction ................................................................................................. 66
3.7.13
Lack of Output .................................................................................................................................. 68
3.7.14
Servo Output Differs When Running an Automatic Test Sequence. ................................................ 68
3.8
Configure Control PIDs ........................................................................................................................ 68
3.8.1
Algorithm Description ...................................................................................................................... 69
3.8.2
Proportional ...................................................................................................................................... 70
3.8.3
Integral .............................................................................................................................................. 71
3.8.4
Differential........................................................................................................................................ 72
INTRODUCTION
3.8.5
3.8.6
3.8.7
3.8.8
3.8.9
3.8.10
3.8.11
3.8.12
3.8.13
3.8.14
3.8.15
3.8.16
3.8.17
3.8.18
3.8.19
3.8.20
3.8.21
3.8.22
3.8.23
3.8.24
IM 1347/1 ISSUE 5
3.9
Configure Channel Mapping ................................................................................................................. 88
3.9.1
Using the Channel Mapping Editor .................................................................................................. 88
3.9.2
Example Selecting a Digital Output to be Controlled by the Test Sequence. ................................ 89
4.1
AVL Fuel Weigher .................................................................................................................................. 90
4.1.1
AVL Fuel Weigher Set-up ................................................................................................................ 90
4.1.2
Channel Configuration...................................................................................................................... 91
4.1.3
Suggested Calculation Channels Derived from Fuel Channels ........................................................ 91
4.2
4.3
4.4
AVL 735 Fuel Mass Flow Meter & AVL 753 Fuel Temperature Controller Modules ..................... 93
4.4.1
System Interface ............................................................................................................................... 93
4.4.2
AVL Fuel Diagnostic Display .......................................................................................................... 95
4.4.3
Maintenance Operations ................................................................................................................... 97
4.4.4
Supporting Documentation ............................................................................................................... 98
4.5
ASAM MCD 3MC Interface .................................................................................................................. 99
4.5.1
Software Installation ......................................................................................................................... 99
4.5.2
Calibration Tool Drive Mapping ...................................................................................................... 99
4.5.3
Communication Configuration. ...................................................................................................... 100
4.5.4
Calibration Tool Timeout Settings.................................................................................................. 100
4.5.5
ASAM MCD 3MC interface Initial Startup .................................................................................... 100
4.6
Electronic Throttle Control ................................................................................................................. 101
4.6.1
Configuration of the Electronic Throttle Control. .......................................................................... 101
4.6.2
Configuration of the Engine Power Unit to use Electronic Throttle Control. ................................. 101
4.6.3
Testing the Electronic Throttle Control .......................................................................................... 102
June 2009
TEXCEL SOFTWARE
INTRODUCTION
5.1
5.2
6.1
Printer Set-up ........................................................................................................................................ 105
6.1.1
Installing a Printer........................................................................................................................... 106
6.1.2
Uninstalling a Printer ...................................................................................................................... 107
6.2
6.3
6.4
7.1
Data Storage on the Texcel .................................................................................................................. 110
7.1.1
The PC Program and Configuration Data Storage .......................................................................... 110
7.1.2
The Texcel Controller Unit Configuration and Logged Data Storage ............................................ 110
7.2
File Handler Option - Automatic Data Transfer ............................................................................. 111
7.2.1
File Handler Utility Installation ................................................................................................... 111
7.2.2
File Handler Default Installation Settings .................................................................................... 112
7.2.3
File Handler Re-configuration ..................................................................................................... 113
7.2.4
File Handler Alternative Configuration Automatic Archive To Host ....................................... 115
8.1
Saving Modifications ............................................................................................................................ 117
8.1.1
Saving Modifications When Using the Main Instrumentation Package ......................................... 117
8.1.2
System Settings that are Not Saved ................................................................................................ 118
8.2
Selecting Display Pages Automatically ............................................................................................... 119
8.2.1
Selecting a Page Using a Calculation ............................................................................................. 119
8.2.2
Selecting a Page from an Automatic Test Using a General Controller ........................................... 120
8.3
EURO 3 & EURO 4 Test sequences .................................................................................................... 120
8.3.1
Configuration for Using the EURO tests. ....................................................................................... 121
8.4
Configuration Details for Sequencer Special Functions .................................................................... 125
8.4.1
Wait for operator checks. ................................................................................................................ 125
8.4.2
External Log Trigger ...................................................................................................................... 126
8.4.3
External Log Synchronisation ........................................................................................................ 126
9.1
9.2
INTRODUCTION
10
IM 1347/1 ISSUE 5
11
June 2009
TEXCEL SOFTWARE
INTRODUCTION
Table of figures
Figure 3-1 Configure Analogue Channels Page ________________________________________________ 13
Figure 3-2 Multi Coder Link Configuration Table _______________________________________________ 15
Figure 3-3 Calculation Editor ______________________________________________________________ 19
Figure 3-4 Calculation syntax - Simple Operators_______________________________________________ 20
Figure 3-5 Calculation syntax - Logical Operators ______________________________________________ 20
Figure 3-6 Digital Output Configuration Page _________________________________________________ 22
Figure 3-7 Channel Mapping Editor _________________________________________________________ 23
Figure 3-8 Digital Display _________________________________________________________________ 24
Figure 3-9 analogue channel calibration page _________________________________________________ 26
Figure 3-10 Check calibration page__________________________________________________________ 33
Figure 3-11 LK3 on DX100 module __________________________________________________________ 34
Figure 3-12 LK1 on Signal Connector Board __________________________________________________ 34
Figure 3-13 Calibration Report _____________________________________________________________ 37
Figure 3-14 Sensor Connection list __________________________________________________________ 38
Figure 3-15 Configuring Analogue Output Channels ____________________________________________ 39
Figure 3-16 Analogue Output calibration page _________________________________________________ 40
Figure 3-17 Analogue Input Calibration Page__________________________________________________ 45
Figure 3-18 HS70 Throttle Actuator showing Type A and Type B Linkage ____________________________ 48
Figure 3-19 HS70 Throttle Actuator showing Type A and Type B Linkage ___________________________ 52
Figure 3-20 Check Calibration Report________________________________________________________ 56
Figure 3-21 Configure Digital Channels Dialog ________________________________________________ 57
Figure 3-22 External Controller Schematic ____________________________________________________ 59
Figure 3-23 External Controller Demand Dialog _______________________________________________ 60
Figure 3-24 External controllers configuration dialog ___________________________________________ 61
Figure 3-25 Example external controller configuration___________________________________________ 67
Figure 3-26 Water control example __________________________________________________________ 67
Figure 3-27 PID configuration page _________________________________________________________ 69
Figure 3-28 General PID Equation __________________________________________________________ 69
Figure 3-29 PID control schematic __________________________________________________________ 70
Figure 3-30 Proportional Term Explanation ___________________________________________________ 70
Figure 3-31 PID term comparison tables ______________________________________________________ 71
Figure 3-32 Integral Term operation _________________________________________________________ 72
Figure 3-33 Differential term operation_______________________________________________________ 73
Figure 3-34 Effect of each PID term _________________________________________________________ 74
Figure 3-35 Proportional Gain Settings _______________________________________________________ 80
Figure 3-36 Optimal proportional gain example ________________________________________________ 81
Figure 3-37 Oscillation Frequencies _________________________________________________________ 81
Figure 3-38 Effects of increasing P or D term __________________________________________________ 82
Figure 3-39 Effects of changing I term ________________________________________________________ 83
Figure 3-40 Inlet valve configuration channels _________________________________________________ 84
Figure 3-41 Cross coupled mode pairs table ___________________________________________________ 87
Figure 3-42 Recommended PID Starting Coefficients ____________________________________________ 88
Figure 3-43 Channel mapping editor _________________________________________________________ 88
Figure 4-1 Fuel Weigher Channel Mapping ___________________________________________________ 91
Figure 4-2 AVL Fuel Unit Connections _______________________________________________________ 93
Figure 4-3 AVL Fuel Unit Diagnostics Display _________________________________________________ 95
Figure 4-4 Power Unit Throttle Control Parameters ____________________________________________ 102
Figure 5-1 Access level passwords __________________________________________________________ 104
Figure 5-2 RTP operating system logins _____________________________________________________ 104
Figure 6-1 Printer setup dialog ____________________________________________________________ 105
Figure 6-2 Print dialog___________________________________________________________________ 106
Figure 6-3 Windows Printer control panel dialog ______________________________________________ 106
Figure 6-4 connecting to network printer_____________________________________________________ 107
INTRODUCTION
IM 1347/1 ISSUE 5
June 2009
107
108
109
109
110
111
111
112
112
113
113
114
114
115
115
116
TEXCEL SOFTWARE
INTRODUCTION
Record of Amendments
The information in this manual will be subject to revision in accordance with alterations
made to the equipment specification or descriptive text.
The edition will be raised when the product specification is changed and the issue will be
raised when the descriptive text is changed.
Users of the manual should ensure that they are in possession of the correct edition and
issue for the equipment in their possession. This information will be provided on the list of
technical documentation supplied when the equipment is dispatched.
Manual
Issue
Date
Details
IM1347
August 2003
IM1347
July 2004
IM1347
April 2005
IM1347/1
June 2005
IM1347/1
April 2008
IM1347/1
June 2009
INTRODUCTION
IM 1347/1 ISSUE 5
1 INTRODUCTION
1.1
Team Leader
Able to oversee operator functions and has access to functions for day-today running.
Supervisor
Instrumentation
Froude
Note:
the associated passwords for the levels listed above can be located in Chapter 5
This manual should be used in conjunction with the IM1346 Texcel Software Operator's Guide
that details the general operating principles of the system.
1.2
June 2009
TEXCEL SOFTWARE
INSTALLATION PROCEDURE
2 INSTALLATION PROCEDURE
This section details the procedure required to install the Texcel system into the test cell. The
Texcel system will be supplied with all software required preinstalled and configured ready for
use, if transducers have been supplied with the equipment then the channels for these
transducers will have already been calibrated.
Where the PC or Texcel controller has been changed or upgraded please refer to section
Error! Reference source not found. Of this manual for details of the software installation
procedure required for the control system.
2.1
Microsoft Windows CD-ROM and Operators Guide with Certificate of Authenticity attached
Microsoft Office CD-ROM and Operators Guide with Certificate of Authenticity attached
Where Froude Hofmann has supplied the PC, the system will be pre-configured and ready to
use once installed and connected up. Where the PC is new or separately supplied consult the
PC documentation for guidance on installing the Windows operating system.
Check the PC base unit and monitor are both selected to the local supply voltage. Note that
some monitors auto-switch between 110 and 220 VAC. Consult the manufacturer's manuals for
further assistance.
Fit mains leads to the base unit and monitor (do not switch on either unit yet).
Connect the VGA monitor lead into the 15 pin graphics 'D' type socket on the base unit.
Connect the mouse and keyboard to the base unit
Fit one end of the modem phone lead to the 'Teleco' socket of the modem, which is preinstalled in a slot in the PC base unit. Note that the other end of the phone lead should be left
disconnected from the phone system until remote support facility is required.
Connect the 9 way 'D' type serial lead (Froude Hofmann Part No.791704) to COM1 of the PC.
Fit the other end to the rear panel of the Texcel controller unit. Dependent on the hardware
platform used the connection point will be:
10
Texcel V4 PLUS
COM 2
Texcel V4 Advantage
COM 2
Texcel V6
Serial Port 2
INSTALLATION PROCEDURE
IM 1347/1 ISSUE 5
Texcel V8
Texcel V10
COM 2
Texcel V12
COM 2
If the COM1 interface socket on the PC is already in use for a serial mouse for example,
connect the serial loom into COM2. (Make a note of the PC serial port connection for future
reference, as the software installation will require the selection of the appropriate
communication port on the PC).
Fit one end of the Ethernet network cable to the first network board located normally in the top
slot of the PC base unit (or the network socket identified for use with the Texcel Controller).
Fit the other end of the network cable assembly to the Ethernet network outlet on the rear panel
of the Texcel Controller unit. For system supplied with a network hub please refer to the
contract documentation to show which hub connections to be used. The cables supplied with a
hub-based network are coloured coded to assist connection.
Where interface to a local area network is required, fit the nominated network loom to the
appropriate socket on the second network card. In most cases the network adapter built into
the motherboard is used for the UIP to RTP connection and the second network card is
provided for customer connection onto their own network.
Note
2.2
June 2009
11
TEXCEL SOFTWARE
2.3
INSTALLATION PROCEDURE
2.4
12
IM 1347/1 ISSUE 5
3.1
Note:
June 2009
To select the current value on a drop down list, it is necessary to double click the
value.
13
TEXCEL SOFTWARE
When the system is initially commissioned. At this time, all the parameters for a particular
channel need setting to their correct values.
When a spare channel is utilised. Normally, most of the parameters will have been
correctly set during the commissioning phase. Parameters that will require setting are the
scan rate, max, logging requirements etc.
During calibration. When a channel is being calibrated, it may be necessary to change the
scan rate or the programmable gain.
the hardware configuration of the board is normally set up during the commissioning
phase only.
The VME hardware is used in the Texcel V6 & V8 control systems only, there are no user
configurable hardware settings on the PCI hardware used in the V4 Advantage and V10 control
systems; all of the channels in these systems are configured under software control.
These analogue input channels can be identified from the Address field of the form
SCC:xx:AI:yy where xx = board number and yy = channel number on the board.
To check the signal conditioning card(s), the system must be shutdown and powered off. (Exit
all configuration pages; select ExitShutdown Texcel Controller before removing the power
to the controller).
Warning: observe anti-static precautions when handling all electronic components
such as signal conditioning card.
Check that the correct multi-coder is fitted for the transducer used.
14
IM 1347/1 ISSUE 5
The following table lists the multi-coders (multi-coloured link blocks) available to configure each
channel of the VME signal conditioning board, E220412A.
Configuration
Colour
Code
Red
Green
Yellow
Blue
Grey
Violet
Orange
Brown
White
Thermocouple
PRT 2 Wire
PRT 3 Wire
Bridge (G=100)
Bridge (G=10)
+/-10V
+/-1V
+/-100mV
User
Stock
No.
791522
791524
791523
791521
791532
791525
791526
791527
791537
X
X
X
X
X
X
X
X
X
X
P
P
P
P
P
P
P
P
P
X
X
X
X
10
11
12
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Depending on the type of transducer connected to each of the 16 channels per VME Signal
Conditioning Board, insert the correct multi-coder into the relevant link field. The following table
cross-references channel numbers to link fields.
Channel
Multi-coder
Channel
Multi-coder
0
J0
8
J8
1
J1
9
J9
2
J2
10
J10
3
J3
11
J11
4
J4
12
J12
5
J5
13
J13
6
J6
14
J14
7
J7
15
J15
Check that the transducer is connected to the correct terminals on the transducer marshalling
board.
Note:
Failing to ensure the above settings are correct may damage the signal conditioning
card or the transducer.
Select the optimum programmable gain. This should be set, such that with the maximum input
applied, the input voltage should be as close to, without exceeding, 10V. If it is not possible to
decide what the optimum gain setting is, it should be set to x 1, as the value can be optimised
when the channel is calibrated.
June 2009
15
TEXCEL SOFTWARE
Scan rate - This is selected from a drop down list of available settings. The scan rate should be
set to match the response of the input signal. Selecting a scan rate that is too low will result in
the signal being distorted, but setting the value too high reduces the number of channels that
can be scanned. The scan rates of thermocouples and PRTs should normally be set in the
range 500 5000mS, with pressure transducers in the range 100 500mS. The scan rate of
control parameters such as speed and torque should always be set to 20mS to ensure the best
control. For Texcel V10 control systems the minimum scan rate can be 10ms and this value
should be used for speed and torque feedback channels to ensure optimum control accuracy.
Maximum change per scan - This parameter is used on the rare occasions where the input
signal is susceptible to noise spikes. All efforts should be made to identify and remove the
cause of the noise rather than using this parameter. If it is required, it should be set to a value
that allows normal signal changes to be processed without being affected, otherwise it should
be set to zero.
Example
16
IM 1347/1 ISSUE 5
Filter factor - This parameter is used to reduce the effect of noise on an input signal. It has the
range of 0 1 where 0.0 represents no filtering and 1.0 represents 100% filtering of the input.
The filter factor should be set as low as possible to give acceptable readings from an input as
increasing the filter factor reduces the ability of an input to respond to new input levels. A filter
factor of 1.0 will totally freeze an input at its current value and should not be used. The
maximum useable value is 0.8.
The high warning torque alarm is set at 120Nm. The alarm dead-band is set
at 5Nm. An alarm log will be generated when the torque reading first exceeds
120Nm. The second log will not be generated until the torque reading has
fallen below 115Nm and then exceeds 120Nm again.
Alarm Override - Some channels are inevitably going to be in an alarm state when the engine
is stationary e.g. engine oil pressure. To enable the shutdown chain to be reset and hence the
engine started, it must be possible to override the alarm threshold on a channel. Setting the
override mode to timed does this. When set to timed, the alarms will be overridden from the
time the shutdown reset button is pressed until the engine has been running for the override
time-out period specified in the currently active power unit. The Texcel User Manual describes
the setting of the alarm override time-out period.
June 2009
17
TEXCEL SOFTWARE
Purpose
Maximum
Frequency
Set-point
1000
1 Hz
Periodic
Flexible/fast logging
24
100 Hz
Rolling Logger
24
100 Hz
Note the set-point logger is controlled by the sequencer. Due to stage switching timing,
continuous 1Hz logging in not guaranteed.
For set-point logging, Sample Point Number and Parameter Number, are logged in the first
two rows respectively of the log data file and can be used by data analysis packages to sort the
channel data. Automatic sorting of channels on Parameter Number during logging can be
selected by enabling the facility in the set-point logger as described in the next section.
3.1.8 Calculations
Texcel supports calculations that run in real time and are used for deriving data from the
measured parameters. They can be processed at up to 100Hz and share the same properties
as measured parameters, i.e. they can be displayed, alarmed, logged etc.
Calculations are held in .clc files in the Calcs directory. Multiple calculation files can be
defined, with the file default.clc being loaded at power up. Other calculations can be loaded
when a test is run, by selecting the file in the Identify Test dialog.
Special log calculations are supported, which are evaluated when a log is taken. They
evaluate the averaged data being logged, rather than instantaneous values.
When configuring a calculated channel, its current calculation is displayed. This is modified by
clicking the Edit Calc button, which displays the calculation editor dialog, shown below. Its
text box displays the current calculation, which can be modified by typing directly into it.
Calculation entry is made simpler by using the dialog buttons that paste their labels directly into
the calculation.
18
IM 1347/1 ISSUE 5
3.1.10 Variables
Variables are named containers for intermediate values in a calculation. The names are
alphanumeric, must start with an alphabetic character (A-Z, a-z) and must not include spaces.
The following are valid variable names
Engine_Is_Running
EngineIsRunning
CorrectionFactor
June 2009
19
TEXCEL SOFTWARE
CorrectionFactor1
cf
And the following are invalid variable names
1CorrectionFactor
Correction Factor
(Includes a space)
C#f
A variable is automatically created the first time its name is encountered. Initially its value is set
to 0. Its value is maintained between evaluations of a calculation. This means that the following
statement is valid and will provide an incrementing count of the TimeIntoTest.
TimeIntoTest = TimeIntoTest +1
Description
Example
Addition
3+2
Subtraction
32
Multiplication
3*2
Division
3/2
1.5
**
Raise to the
power of
3 ** 2
Description
Example
<
Less than
3<2
FALSE (0)
>
Greater than
3>2
TRUE (1)
<>
Not equal to
3 <> 2
TRUE (1)
==
Equal to
3 == 2
FALSE (0)
And
Logical and
3 and 2
TRUE (1)
Or
Logical or
3 or 2
TRUE (1)
The result of a logical operation is normally used as part of a conditional statement, but can be
used directly in a simple statement.
Example
20
IM 1347/1 ISSUE 5
returns natural logarithm for positive values of X, e.g. ln(2.7183) returns 1.00000
June 2009
21
TEXCEL SOFTWARE
22
IM 1347/1 ISSUE 5
This modification has mapped the control of the Cooling Fan to the calculation that has the
address SYSV:0:RU:06.
To apply changes to the system channel mapping, the Texcel Controller must be restarted,
select the ExitRestart The Texcel Controller. After approximately two minutes Speed and
Torque should appear on the manual control panel indicating the system is restarted correctly.
Check that the calculation file includes the definition for the calculation.
1. Select the menu option UtilitiesWindows Explorer.
2. Open the folder \Data\Calcs.
3. Edit the file default.clc. This is the default set of calculations applied from power up. If
the calculation is required for a particular test, the calculation may reside in an alternative
calculation file.
4. Check for the presence of a calculation beginning R:06. If one exists, exit the edit without
changes and skip the next step.
5. Where the calculation does not yet exist, enter the following
R:06 Cooling_Fan_Calc
Return 1
6. Save the file and exit the editor.
June 2009
23
TEXCEL SOFTWARE
24
IM 1347/1 ISSUE 5
2. Using a digital output display item on the instrumentation page (or via UtilitiesDigital
Output Monitor), select Cooling Fan for display.
3. Run the engine. Increase Speed above 2000 rpm the Cooling Fan should turn on.
4. Reduce the Speed below 2000 rpm. The Cooling Fan should turn off.
5. The Cooling Fan can be turned on or off manually using the digital output display item
but the output reverts to the correct state when the Speed threshold of 2000 rpm is
crossed.
3.2
June 2009
25
TEXCEL SOFTWARE
26
1.
2.
3.
Select the channel to be calibrated by clicking on the Channel Name field and
selecting a channel from the Channel Select dialog.
4.
5.
Click the Start Cal button. The Calibration Status will read Uncalibrated.
3.2.2
IM 1347/1 ISSUE 5
6.
7.
If the ADC value is less than 60% or greater than 99%, click the Abort Cal button.
Select Configure Channel and increase or decrease the Programmable Gain as
necessary. Exit the configuration page and restart the calibration.
8.
9.
Type the equivalent engineering unit value for the input into the Engineering unit
text box.
10.
Wait for a few seconds until the ADC value has stabilised (less than +/- 1%) then
click the Accept Point button. The Calibration Status will now read Point 1
Taken.
11.
Apply a different simulated input to the channel (second point). This is normally the
maximum value for the channel, but can be any value within the expected input range
provided that it differs from the first input by at least 10% of the engineering unit
range of the channel. Type the equivalent engineering unit value for the input into the
Engineering unit text box
12.
Wait for a few seconds until the ADC value has stabilised (less than +/- 1%) then
click the Accept Point button. The Calibration Status will now read Point 2
Taken.
13.
For most transducers, two calibration points are sufficient. The two points recorded so
far normally cover the both ends of the expected operating range of the input. Where
the transducer gives a linear response, all readings between the two calibration
points will be correct. Where the transducer has a non-linear response, other points
may be taken as necessary (up to 40 points per channel). Adjust the simulated input
and select Accept Point for additional points as necessary. Note that the
Calibration Status will update to show each calibration point that is accepted the
calibration engineering and adc break-points will be listed in the table at the lower left
side of the page.
14.
Click the End Cal button to calculate the new calibration parameters. These will be
automatically saved to the calibration file. The calibration for this channel is complete.
Aborting A Calibration.
If it is necessary to abort a calibration for any reason, click the Abort Cal button. The
parameters from the previous calibration will automatically be restored
June 2009
27
TEXCEL SOFTWARE
Replacement or re-sitting of a PRT cold junction sensor should result in its re-calibration. All
thermocouples that refer to this PRT for cold junction compensation should be checked and recalibrated as necessary.
Replacement of connection cable for resistance type transducers should require a check and
re-calibration if required for these types of channel. For example, a change in a PRT or wiring
between this device and the Signal Conditioning Card should result in a re-calibration.
A change in thermocouple of the same type should not normally require re-calibration.
A change in engine with a different throttle range should not require re-calibration of the throttle
actuator feedback (or output demand) signal. The calibration on the throttle and dynamometer
demand output and feedback signals is normally a commissioning time requirement only. A
change in throttle actuator ranging is achieved using the RUN / MIN / MAX key-switch and the
MIN and MAX potentiometer dial adjusters on the In-Cell Module. The demand output and
feedback calibration is unaffected display ranges are adjusted automatically.
3.2.6 Calibration Error ADC is saturated - the input level cannot be determined
accurately.
A calibration point cannot be taken when the input exceeds the range of the ADC (equivalent to
an ADC Value of 65535). There are two possible solutions to this problem:
1. Reduce the input signal and take a calibration point for a smaller engineering value
2. If the channel is on a signal-conditioning card (Address field commences with either
SCC:. or PSC), select Abort calibration, choose Configure Channel and reduce
the Programmable Gain. Repeat the calibration process.
3. If the channel is Torque on the Dyno Throttle Controller (DTC) board, reduce the Torque
Gain switch setting on the front of the board.
28
IM 1347/1 ISSUE 5
4. For older systems the gain is configured using a select-on-test resistor located on a
conditioning board In-Cell, (consult the previous hardware manuals for select and fitting
instructions).
3.2.7 Calibration Error ADC is grounded - the input level cannot be determined
accurately.
A calibration point cannot be taken when the input drops below the measuring range of the
ADC. Since most ADCs are bi-polar this actually means that the input signal from the
transducer is beyond the negative signal range for the current gain of the channel. The two
most common reasons for this are the transducer is not connected to the input signal cable or
is connected incorrectly. For example, for temperature channels the thermocouple may not be
plugged into the In-Cell transducer box.
Check the transducer is connected correctly. This fault may also be due to too much gain
selected on the channel. Refer to the previous section for the corrective measures.
June 2009
29
TEXCEL SOFTWARE
Normally, for a 16 bit bi-polar ADC this will result in a reading around 32000 ADC bits (+/2000). This value should continuously update with slightly different readings at the frequency
specified by the Scan Rate field in the Configure Analogue Channel page.
If the value does not read close to this value this may indicate the channel has a connection
fault between the signal input (at the point where the input is shorted) and the connections onto
the signal-conditioning card. Check all interconnecting looms.
If the value is not updating this implies the channel is not scanned check the frequency
specified by the Scan Rate field in the Configure Analogue Channel page. Check other
channels if these are also frozen at non-zero ADC Bits values, exit the calibration page,
select ExitRestart the Texcel Controller.
If the channel ADC Bits value is updating with roughly the correct range value but reads
incorrectly when the transducer is connected, this indicates a transducer or connection fault
with the transducer itself try a different transducer to confirm this.
The hardware gain of the signal-conditioning channel should be adjusted to maximise the range
of ADC values given for the expected operating signal range of the transducer. It is
recommended to simulate the maximum expected transducer input signal and adjust the gain
to give the maximum ADC value possible without saturating the channel before attempting the
calibration process.
When calibration points are taken the configured Scan Rate and Filter Factor are effectively
disabled the channel will be read at the fastest scan rate with no filtering, calibration points
are taken from a 1 second average of 50 readings. When diagnosing noise or offset related
faults on a channel it is advisable to temporarily set the Scan Rate to at least 0.5 second and
set the Filter Factor to 0 to disable it. When diagnostics and calibration are complete, the
original Scan Rate and Filter Factor may be restored.
Channels should not have an excessive Filter Factor set. Values of 0.2 are the maximum
recommended for control signals such as Torque, temperature and pressure channels should
have a maximum Filter Factor no greater than 0.4. The overall response of a given channel
depends on the combined values of the Scan Rate and Filter Factor settings.
Note:
Use of the scrolling trend graph object is recommended when diagnosing noise related
problems. Similarly the Min/Max Tracking object can be used to capture the minimum
and maximum readings for a channel with a constant signal input this is useful when
determining peak-to-peak noise for example. Finally, assigning high and low warning
alarms to monitor a channel will detect an out of range value that occurs infrequently
for perhaps a single reading only. The Rolling Store may also be configured to
monitor a particular channel at up to 50Hz (although a manual test must be identified
and started to enable the user to capture this data).
More than one channel in the instrumentation list may be configured to scan the same physical
input (i.e. channels may have identical hardware Address specification). This may be useful
to provide temperature transducer readouts in both Celsius and Fahrenheit for example. Note
that all channels require separate calibration. Re-calibration of one channel does not affect the
existing calibration of other channels that are configured to read the same physical input
Address.
The Cold Junction may be calibrated in a different temperature scale to that of thermocouple
channels that refer to it for compensation.
30
IM 1347/1 ISSUE 5
1.
2.
3.
Select the Configure Channel. Set the Filter Factor to zero (i.e. remove all
filtering).
4.
Enter the Minimum torque value. (0 uni-directional dyno, maximum negative value
bi-directional dyno e.g. -500 Nm)
5.
6.
7.
Optionally, if the load arm display is shown, enter the length of the load arm (this is
normally derived from the contract drawings or is marked on the load arms
themselves). The acceleration due to gravity is defaulted to the metric system (this
Constant can be adjusted to give read-outs in other scales). The resulting mass M is
displayed. When a calibration is in progress the mass M is the equivalent of the
current engineering point entered in the Engineering Value field (i.e. the mass to be
June 2009
31
TEXCEL SOFTWARE
loaded on the arm for this calibration point). When a calibration is not in progress, the
mass M is equivalent to the Current Value for the channel (i.e. the equivalent mass
calculated from the current engineering value based on the current calibration).
32
8.
For systems fitted with a Dyno Throttle Controller card. Load the maximum
calibration weight onto the load arm equivalent to the maximum torque required.
Adjust the Torque Gain switch on the front of the DTC board to achieve an ADC
reading as close to but less than 65535. Remove the calibration weights from the
load arm.
9.
10.
Enter 0 into the Engineering Unit value field for a uni-directional dynamometer. If
the dynamometer is bi-directional (i.e. the load cell has to measure negative and
positive torque), load the maximum calibration weight onto the relevant load arm.
Enter the minimum torque (negative value) into the Engineering Unit value field.
11.
Wait for the ADC value to stabilise to within 10 bits and click the Accept button.
12.
Load the maximum calibration weight onto the relevant load arm equivalent to the
maximum torque required (opposite load arm for bi-directional dynamometer). Enter
the maximum torque into the Engineering Unit value field.
13.
Wait for the ADC value to stabilise to within 10 bits then click the Accept button.
14.
15.
16.
17.
Remove the dynamometer load arms prior to running the system. Confirm the
Torque channel still reads zero. A non-zero value may indicate load arm imbalance
or other mechanical inaccuracy. (Refer to the dynamometer technical manual).
18.
The calibration accuracy should now be checked. Select the Check Cal Report
option. Confirm the calibration points listed are correct. Enter the calibration point to
be checked, load the dynamometer with the required mass then press Accept.
19.
IM 1347/1 ISSUE 5
June 2009
33
TEXCEL SOFTWARE
Prior to calibrating the Cold Junction channel check that a link exists in position A on
LK3 found on the DX100 module. This selects external cold junction compensation and if
not fitted will prevent calibration of the Cold Junction channel on the Signal Connector
Board.
2.
Select the Cold Junction channel (DI0:01:AI: 47) on the Calibrate Analogue Inputs
page.
34
IM 1347/1 ISSUE 5
E.g.
C
Millivolts
60
2.436
100
4.095
150
6.137
200
8.137
250
10.151
500
20.640
750
31.214
1000
41.268
1200
48.825
Table 3
Note:
June 2009
35
TEXCEL SOFTWARE
Do not attempt this calibration until the Cold Junction channel has been calibrated.
36
IM 1347/1 ISSUE 5
June 2009
37
TEXCEL SOFTWARE
Note that the Cold Junction field will only appear for thermocouple inputs (select the
appropriate cold junction PRT channel by clicking on the cold junction field and selecting the
appropriate channel from the list of transducers given.
The Permitted % Error field can be adjusted by clicking on this field and typing in a
percentage value (this value may also be adjusted in the calibration page)
The percentage calibration error is calculated as
Error% =
If this is greater than the Permitted % Error the check calibration fails.
The lower left section Calibration Data lists each of the calibration break points. This is the
Engineering Value entered for each point and the signal level in terms of ADC Bits or % full
scale of the ADC (the full range of a 16 bit ADC is 0 to 65535).
The lower right section lists the calibration Check-Points. When a channel is re-calibrated the
checkpoint data is cleared (existing checkpoint data may also be cleared using the ClearAll
button). As checkpoints are entered using the Accept button they will appear as a line in this
section.
Click on the Print Report button to send the completed report to the default printer defined by
the Printer Setup item in the Utilities menu.
Click on the OK button to close the report and return to the calibration screen.
3.3
38
IM 1347/1 ISSUE 5
June 2009
39
TEXCEL SOFTWARE
40
1.
Select the output channel required by clicking on the Channel Name field. The
correct channel name for the output can be derived using the UtilitiesSensor
Connection List option.
2.
If the output channel has an associated analogue feedback channel, this may be
selected into the Feed-back Channel field. This channel may also be located using
the UtilitiesSensor Connection List option. Note that the feedback channel must
be calibrated prior to calibrating the output channel to achieve a corresponding
correct reading (this may not always be possible depending on the type of
actuator).
3.
Click on the Start Cal button to drive the output. The initial output position will be
set.
Note:
4.
Note:
IM 1347/1 ISSUE 5
Once the Start Cal option has been chosen, the output channel is no longer linked to
the normal control demands. For the example shown in Figure 3-16, the throttle output
will be driven from the calibration page and not the throttle demand as specified by the
manual control panel demand controls. The output is re-linked to the normal controller
when the End Cal or Abort Cal buttons are pressed.
Adjust the output minimum position for the first calibration point. (This may require a
visual check of the actuator travel to achieve the desired minimum position).
There are two methods of adjusting the output signal. For coarse adjustment, use the
mouse left button to click and drag the bar on the Adjust DAC Output field (note
that the output only updates each time the mouse button is released). For fine
adjustment click on the Change Output By fields to increment or decrement the
output. Note that this applies to the Current DAC Reading value (DAC = Digital to
Analogue Converter).
The full range of the DAC output setting is 0 to 65535. This corresponds to an output
voltage of 0 to 10 volts or 10 Volts depending on the board type or output channel
type. For example, on the DTC board the main control signals for throttle and
dynamometer are bi-polar outputs. The output ranges from roughly 32768 to 65535
for zero to full range channel output. The Speed Repeater and Torque Repeater
outputs on the DTC are uni-polar however; the DAC output range is from 0 to 65535.
5.
When the correct minimum position is achieved, click on the Accept Point button.
The Calibration Status will display Point 1 Taken.
6.
Re-adjust the output to achieve the maximum position of the actuator for the second
calibration point.
7.
When the maximum position is achieved, click on the Accept Point button. The
Calibration Status will display Point 2 Taken.
8.
Click on the End Cal button. The Calibration Status will display Calibrated and
the calibration date and time will update to the current time. If a Next Cal. Due entry
was present prior to calibrating the channel, this will update to the next cal. date
based on the UtilitiesCalibration ParametersCal Expiration Period field. A
warning message will be given when the channel requires re-calibration (as shown by
the ViewView Status Messages option). To disable this facility, clear the Next
Cal. Due field.
9.
The calibration may be aborted at any time during the above steps prior to pressing
the End Cal button by pressing the Abort Cal button. The previous calibration will
still apply.
10.
On completing a calibration, the calibration instrument details may be entered into the
fields in the central region of the calibration page.
11.
To check the actuator output calibration, press the Test button. The output will drive
between the two demands specified in the UtilitiesCalibration
ParametersAnalogue Output Test Parameters section. Press the Stop Test to
stop the output test. Note that when the output is driven in test mode, the normal
controller demands are ignored. This test mode is useful to check the calibration and
adjust the response of actuators.
June 2009
41
TEXCEL SOFTWARE
all ancillary type equipment including external control outputs do not require the shutdown chain to be reset
1.
Select the analogue output channel Engine Coolant E/P on the System
ConfigurationCalibrate Analogue Outputs page.
2.
3.
Use the Adjust DAC Output controls to set the engine coolant control valve to its
minimum position. This should normally be at the end of its mechanical end stop,
(see note below).
Warning: Minimum Position depends on the type of valve and its installation. For failsafe operation, the Minimum Position should be configured to provide
maximum cooling to the engine. This means that zero volt input to the valve
controller (i.e. power failure or wiring fault) should fail to a safe position.
4.
5.
Adjust the DAC Output until the valve is in its maximum position (this should
normally be the position at which the minimum amount of cooling is provided).
6.
7.
8.
Fill in the calibration details in the centre fields for any equipment used
The Engine Coolant E/P channel is now calibrated. This output channel can now be selected
in the external controller page. Select the channel into the System ConfigurationConfigure
External ControllersWater ControllerConfigureConfigure ChannelsOutput
Channel field.
42
3.4
IM 1347/1 ISSUE 5
Throttle and Dyno Setup for In-Cell Power Module Box - E320108B
This In-Cell Power Module Box is easily identified as it has MIN and MAX potentiometers on
the Front Panel.
Initial calibration of the electronics and mechanical set-up of the throttle actuator (normally
at commissioning time only)
This procedure is only required on initial commissioning time or if any system component is
replaced related to the throttle including: DTC board / In-Cell Box or Servo Board / Throttle
Actuator.
Warning: The following sections make use of the In-Cell Box key-switch, which
causes rapid, extreme movements of the throttle actuator. Make sure that all
personnel are clear of the throttle actuator and drive system before
performing this procedure. The instructions should be followed to avoid
mechanical damage to the throttle actuator or engine throttle mechanisms.
Note:
fly-by-wire throttle systems that do not use the TX21 / HS70 actuators normally
require the re-linking of the In-Cell Box Servo Board for the correct voltage or current
signal output. The calibration procedure in this section may also differ to attain the
signal range required by the external engine throttle system. The throttle feedback
signal calibration is normally unaffected.
Press the throttle actuator thermal trip (i.e. disable the throttle actuator red button)
2.
Disconnect the throttle mechanical linkage at the TX21 (or HS70) throttle actuator
arm. Confirm the linkage is clear of the actuator arm.
3.
Press the throttle actuator thermal trip reset (i.e. enable the throttle actuator black
button)
4.
Open the In-Cell Box door, on the Power Module (E220418A), fit link LK1-A.
Disconnect LK2 and momentarily short LK2-A for 1 second. Check the actuator arm
moves against the mechanical stop (Note that the actuator may drive against the
clutch).
5.
Set the links LK1-C and LK2-C. Check the actuator drives against the opposite
mechanical end stop (Note the actuator may drive against the clutch).
6.
Re-fit the links LK1-B and LK2-B. This proves the output stage of the In-Cell Box
electronics and the throttle actuator drive motor and circuit are functional.
June 2009
43
TEXCEL SOFTWARE
7.
Press the throttle actuator thermal trip (i.e. disable the throttle actuator red button).
Turn the key on the In-Cell Power Module Front Panel to the Run position.
2.
Press the Reset button or turn the Reset key switch to obtain a reset of the Texcel
shutdown chain. Check that the Reset lamp remains on. If the Reset lamp turns
off, clear all the interlocks that are in fault on the shutdown chain.
Note:
In the case of Texcel V6 and V8 control systems, the shutdown chain can be
overridden electrically by inserting a wire link between SD2A to OR1B in place of the
connectors either at the in cell box terminals or on the orange connector block located
on the DTC I/FACE panel at the rear of the Texcel Controller unit. This will override
ALL safety interlocks on this connector block.
3.
Depending on which Texcel system you are using either turn the manual control
panel key-switch to the Enable position or press the Enabled pushbutton on the
Manual Control Panel.
4.
5.
Connect a voltmeter to TP4 (THDEM Throttle Output) and TPAG (0V) on the Servo
Board (E220436B). (Where possible, position the voltmeter such that it can be read
from the Texcel User Interface PC).
6.
7.
Press the Start Cal button. Adjust the output to achieve 0V at TP4 (10mV). Press
the Accept Point button.
8.
Adjust the output to achieve as close to 10V as possible at TP4 (30mV). Press the
Accept Point button then press the End Cal button.
9.
Enter the calibration details for the voltmeter used in the centre fields of the
calibration page.
Warning: After output calibration is completed, any override wire link should be
removed and the original shutdown interlock signals refitted prior to running
the system.
44
IM 1347/1 ISSUE 5
On the In-Cell Power Module Box Servo Board (E220436B), adjust the VR1 MIN
potentiometer fully anti-clockwise and VR2 MAX potentiometer fully clockwise (a
small click can be heard once per revolution when these potentiometers are at the
end of travel).
2.
Set the In-Cell Power Module Front Panel Min potentiometer to 0% position (fully
anti-clockwise), the Max potentiometer to the 100% position (fully clockwise).
Release the locking levers to move the potentiometers, re-apply them when
adjustment is complete.
3.
4.
On the In-Cell Power Module Box Servo Board (E220436B), connect a voltmeter to
TP3 (THPOS Throttle Feed-back) and TPAG (0V).
5.
Open the throttle actuator access door. Move the throttle actuator arm to the
minimum position until TP3 reads 0.2V (50mV). If adjustable mechanical end stops
are fitted, unlock and adjust the minimum stop to match the current arm position.
6.
7.
8.
Click on the Start Cal button then click the Accept Point button for the first
calibration point.
June 2009
45
TEXCEL SOFTWARE
9.
Move the throttle actuator arm to the maximum position until TP3 reads -9.8V
(50mV). If adjustable mechanical end stops are fitted, unlock and adjust the
maximum stop to match the current arm position.
10.
Adjust the MAX potentiometer on the servo board to -10V at TP3 (5mV).
11.
On the Texcel User Interface PC, confirm the Engineering Value is set at 100%,
click the Accept Point button for the second calibration point. Click the End Cal
button to save and apply the calibration.
12.
Enter the calibration details for the voltmeter used in the centre fields of the
calibration page.
Set the throttle demand to 0% using the Test ControlDemand Control option.
2.
Confirm the mechanical linkage is clear of the TX21 / HS70 throttle actuator arm.
Move the actuator arm to the fully closed position.
3.
Press the throttle actuator thermal trip reset (i.e. enable the throttle actuator black
button)
4.
5.
6.
On the In-Cell Box Servo Board (E220436B), connect an oscilloscope to TP3 with
respect to TPAG. Set the time-base to 0.5 S/division, and the Y-axis to 0.5 V/division.
7.
Adjust VR4 GAIN and VR3 DMP potentiometers to obtain the best response from
the actuator. The optimum setting in most cases is as follows. Wind VR3 DMP fully
clockwise (maximum damping). Wind VR4 GAIN clockwise until oscillation on the
rising and falling edge of the signal can be seen. Wind the gain anti-clockwise until
the oscillation is no longer visible (approximately a quarter of a turn). There should be
little or no overshoot.
8.
9.
This completes the calibration of the electronics system. The second part of the calibration
process should now be performed as described in the following section.
46
IM 1347/1 ISSUE 5
The following list of precautions should be observed when performing the throttle calibration
procedure. One or more errors will almost certainly lead to inaccuracies in the throttle
calibration.
Check the Bowden cable outer sheath is securely fixed and has no movement at the
engine throttle bracket or at the connection to the throttle actuator.
Check the cable attachment point to the throttle actuator is set at the correct height to
match the height of the cable connection to the actuator arm at 25% throttle setting.
The cable path should be as straight as possible. Avoid sharp bends in the cable. Where
the cable length is several metres, the cable should supported by attachment to stationary
fixed points that are free from vibration.
Check the linkage does not touch any other part of the actuator arm apart from the
connection point. Particularly, check for fouling on the spindle or mechanical end stop
between 70% to 100% throttle.
Check that actuator is free from mechanical wear and is regularly serviced.
At 0% and 100%, check the actuator arm is not making contact with the mechanical end
stops of the actuator or the linkage is against the stops on the engine throttle as this may
lead to inaccuracies.
Check that the throttle actuator loom has two separately shielded cables for motor and
feedback potentiometer. The shields should be connected at the In-Cell box terminals.
For a rod linkage, check there is no play in the linkage. Check for wear on all rose joints or
loose connections. Check that the linkage between the actuator and the engine throttle
lever is free to move an does not touch any other equipment when the throttle actuator is
moved over the full range of travel.
1.
2.
Press the throttle actuator thermal trip (i.e. Disable the throttle actuator red button)
June 2009
47
TEXCEL SOFTWARE
3.
Referring to the following Figure 3-18, the linkage is normally available in two forms;
Type A rod linkage with rose joint or, Type B Bowden cable. Slacken off the
retaining nut on the link to the throttle arm. For cable (Type B) also disconnect the
cable clamp (items 44-47).
4.
Attach the engine throttle to the linkage. Slide the rose joint or cable bracket up the
actuator arm such that the arm can be moved to achieve the full travel of the linkage.
5.
Using a metal rule, measure the linkage travel from engine throttle fully closed to
engine throttle fully open.
6.
7.
Move the actuator across its full range (between each mechanical end stop), offer up
the metal rule and mark off the approximate point on the arm to connect the throttle
linkage to achieve the desired travel previously measured.
Figure 3-18 HS70 Throttle Actuator showing Type A and Type B Linkage
48
8.
9.
Connect the throttle linkage to the arm at the point marked. For cable (Type B) also
reconnect the cable clamp (items 44-47). Any offset between the arm and the linkage
should be adjusted out using the linkage length adjustment. For a cable linkage this is
IM 1347/1 ISSUE 5
normally a threaded adjustment, (items 44-47). For a rod system this is normally
achieved either at the rose joint collar or a threaded length adjuster between the
throttle actuator and the engine throttle. This adjustment should result in the engine
throttle resting against its full closed mechanical stop.
10.
Move the throttle arm to its maximum mechanical end stop; the linkage should push
the engine throttle against its mechanical stop. Re-adjust the linkage connection point
to the actuator arm and the linkage length as necessary.
Move the throttle actuator arm so that the engine throttle is at the closed position but
does not touch the engine throttle mechanical stop (use a feeler gauge if necessary).
2.
On the In-Cell Power Module Box Servo Board (E220436B), connect a voltmeter to
TP3 (THPOS Throttle Feed-back) and TPAG (0V).
3.
Unlock and adjust the In-Cell Box MIN potentiometer to achieve 0V at TP3
(10mV). Lock the MIN potentiometer at this position.
4.
Move the throttle actuator arm so that the engine throttle is at the fully open position
but does not touch the engine throttle mechanical stop (use a feeler gauge to ensure
this if necessary).
5.
Unlock and adjust the In-Cell Box MAX potentiometer to achieve -10V at TP3
(10mV). Lock the MAX potentiometer at this position.
Press the throttle actuator thermal trip reset (i.e. Enable the throttle actuator black
button)
2.
Turn the key on the In-Cell Power Module Front Panel to the MIN position. Confirm
the engine throttle is driven full closed, check the throttle actuator is not driving
against the actuator or engine throttle mechanical stops or the actuator clutch. Recheck the engine throttle mechanical stop clearance if required. (Make minor
readjustments to the MIN potentiometer if necessary).
3.
Turn the key on the In-Cell Power Module Front Panel to the MAX position. Confirm
the engine throttle is driven full open, check the throttle actuator is not driving against
the actuator or engine throttle mechanical stops or the actuator clutch. Re-check the
engine throttle mechanical stop clearance if required. (Make minor readjustments to
the MAX potentiometer if necessary).
4.
Turn the key on the In-Cell Power Module Front Panel to the RUN position.
5.
Press the Reset button or turn the Reset key switch to obtain a reset of the Texcel
shutdown chain. Check that the Reset lamp remains on. If the Reset lamp turns
off, clear all the interlocks that are in fault on the shutdown chain.
6.
Depending on which Texcel system you are using either turn the manual control panel
key-switch to the Enable position or press the Enabled pushbutton on the Manual
Control Panel.
7.
June 2009
49
TEXCEL SOFTWARE
8.
Use Test ControlDemand Control to set the throttle demand to 50%, confirm
Throttle Position reads 50% (0.5%).
9.
Set the throttle demand to 100%, confirm Throttle Position reads 100% (0.5%).
10.
Set the throttle demand to 0%, confirm Throttle Position reads 0% (0.5%).
11.
12.
Note:
The hardware shutdown chain is defeated until the In-Cell box key-switch is set to the
Run position. Turning the key-switch to Min or Max will immediately break the
shutdown chain thereby shutting down the engine if running.
Press the Reset button or turn the Reset key switch to obtain a reset of the Texcel
shutdown chain. Check that the Reset lamp remains on. If the Reset lamp turns
off, clear all the interlocks that are in fault on the shutdown chain.
2.
3.
Select the channel Dyno Ctrl Op on the Analogue Output Calibration page.
4.
Connect an ammeter to the Dyno Ctrl Op output the Address field in the first
section of the page shows the relevant output.
5.
6.
7.
8.
Warning: Do not leave the dynamometer output at high current setting for more than a
minute without first turning on the dynamometer water-cooling as this may
result in permanent damage to the dynamometer.
9.
10.
11.
Fill in the calibration details in the centre fields for any equipment used
50
Note:
3.5
IM 1347/1 ISSUE 5
When the Start Cal button is pressed the dynamometer output channel is under the
manual control in the analogue output calibration page, the dynamometer demand setpoint set by the manual control panel is ignored. When the End Cal button is pressed,
control of the output reverts to that set on the manual control panel (or zero demand if
the RUN indicator is off).
Throttle and Dyno Setup for In-Cell Power Module Box - E320175A
This In-Cell Power Module Box is easily identified as it has MIN and MAX pushbuttons with
LEDs on the Front Panel.
Once the Learn procedure has been successfully performed the Throttle Output and the
Throttle Position channels will be automatically calibrated.
This procedure must be used for initial commissioning and subsequent engine changes. It can
be performed without the Texcel Shutdown Chain reset.
Warning: The following sections make use of the In-Cell Box key-switch, which causes
rapid, extreme movements of the throttle actuator. Make sure that all
personnel are clear of the throttle actuator and drive system before
performing this procedure. The instructions should be followed to avoid
mechanical damage to the throttle actuator or engine throttle mechanisms.
The following list of precautions should be observed when performing the throttle calibration
procedure. One or more errors will almost certainly lead to inaccuracies in the throttle
calibration.
Check the Bowden cable outer sheath is securely fixed and has no movement at the
engine throttle bracket or at the connection to the throttle actuator.
Check the cable attachment point to the throttle actuator is set at the correct height to
match the height of the cable connection to the actuator arm at 25% throttle setting.
The cable path should be as straight as possible. Avoid sharp bends in the cable. Where
the cable length is several metres, the cable should supported by attachment to stationary
fixed points that are free from vibration.
Check the linkage does not touch any other part of the actuator arm apart from the
connection point. Particularly, check for fouling on the spindle or mechanical end stop
between 70% to 100% throttle.
Check that actuator is free from mechanical wear and is regularly serviced.
June 2009
51
TEXCEL SOFTWARE
At 0% and 100%, check the actuator arm is not making contact with the mechanical end
stops of the actuator or the linkage is against the stops on the engine throttle as this may
lead to inaccuracies.
Check that the throttle actuator loom has two separately shielded cables for motor and
feedback potentiometer. The shields should be connected at the In-Cell box terminals.
For a rod linkage, check there is no play in the linkage. Check for wear on all rose joints or
loose connections. Check that the linkage between the actuator and the engine throttle
lever is free to move and does not touch any other equipment when the throttle actuator is
moved over the full range of travel.
1.
2.
Press the throttle actuator thermal trip (i.e. disable the throttle actuator red button)
3.
Referring to the following Figure 3-18, the linkage is normally available in two forms;
Type A rod linkage with rose joint or, Type B Bowden cable. Slacken off the
retaining nut on the link to the throttle arm. For cable (Type B) also disconnect the
cable clamp (items 44-47).
Figure 3-19 HS70 Throttle Actuator showing Type A and Type B Linkage
52
IM 1347/1 ISSUE 5
4.
Attach the engine throttle to the linkage. Slide the rose joint or cable bracket up the
actuator arm such that the arm can be moved to achieve the full travel of the linkage.
5.
Using a metal rule, measure the linkage travel from engine throttle fully closed to
engine throttle fully open.
6.
7.
Move the actuator across its full range (between each mechanical end stop), offer up
the metal rule and mark off the approximate point on the arm to connect the throttle
linkage to achieve the desired travel previously measured.
8.
Disconnect the throttle mechanical linkage at the TX21 (or HS70) throttle actuator
arm. Confirm the linkage is clear of the actuator arm.
9.
10.
Connect the throttle linkage to the arm at the point marked. For cable (Type B) also
reconnect the cable clamp (items 44-47). Any offset between the arm and the linkage
should be adjusted out using the linkage length adjustment. For a cable linkage this is
normally a threaded adjustment, (items 44-47). For a rod system this is normally
achieved either at the rose joint collar or a threaded length adjuster between the
throttle actuator and the engine throttle. This adjustment should result in the engine
throttle resting against its full closed mechanical stop.
11.
Move the throttle arm to its maximum mechanical end stop; the linkage should push
the engine throttle against its mechanical stop. Re-adjust the linkage connection point
12.
Turn the Key on the In-Cell Power Module Front Panel to the Learn position.
13.
Open the throttle actuator access door. Move the throttle actuator arm to the
minimum position.
14.
Press the Min pushbutton on the In-Cell Power Module Front Panel.
15.
16.
Press the Max pushbutton on the In-Cell Power Module Front Panel.
17.
Press the throttle actuator thermal trip reset (i.e. enable the throttle actuator black
button).
18.
19.
Turn the Key on the In-Cell Power Module Front Panel to the Check position.
Note.
Flashing LEDs on the Min and Max pushbuttons either indicate that the throttle
actuator has not been calibrated or the calibration procedure failed.
June 2009
53
TEXCEL SOFTWARE
1.
Ensure the Key on the In-Cell Power Module Front Panel is switched to the Check
position.
2.
Add the Throttle Position channel to one of the Texcel Instrumentation pages.
3.
Press the Min pushbutton on the In-Cell Power Module Front Panel until the throttle
actuator arm has moved to the minimum position. Monitor the Throttle Position
channel.
4.
Press the Max pushbutton on the In-Cell Power Module Front Panel until the throttle
actuator arm has moved to the maximum position. Monitor the Throttle Position
channel.
5.
Turn the Key on the In-Cell Power Module Front Panel to the Run position.
3.5.3 Checking the Throttle Control from the Manual Desktop Controller
1.
Ensure the Key on the In-Cell Power Module Front Panel is switched to the Run
position.
2.
Press the Reset pushbutton on the Manual Desktop Controller to obtain a reset of
the Texcel shutdown chain.
3.
4.
Press the Run button on either the Manual Control Panel or the Manual Desktop
Controller.
5.
Add the Throttle Position channel to one of the Texcel Instrumentation pages.
6.
Turn the Throttle Rotary Encoder clockwise on the Manual Desktop Controller and
check that the throttle actuator arm moves towards the maximum position. Monitor the
Throttle Position channel.
7.
Turn the Throttle Rotary Encoder anticlockwise on the Manual Desktop Controller and
check that the throttle actuator arm moves towards the minimum position. Monitor the
Throttle Position channel.
54
1.
Ensure the Dyno Water Pressure digital input is ON (ELMO committed I/O).
2.
3.
Operate the Reset button on the Manual Desktop Controller. Check that the Reset
lamp remains on. If the Reset lamp turns off, clear all interlocks that are in fault on
the shutdown chain.
IM 1347/1 ISSUE 5
4.
Press the Enabled button on the Manual Control Panel and check the indicator
remains on.
5.
Select Position on the Throttle and Position on the Dyno from the Manual Control
Panel.
6.
Press the RUN button on either the Manual Control Panel or the Manual Desktop
Controller and check the indicator remains on.
7.
Select the channel Dyno Ctrl Op on the Analogue Output Calibration page.
8.
Connect an ammeter to the Dyno Ctrl Op output the Address field in the first
section of the page shows the relevant output.
9.
10.
11.
12.
Warning: Do not leave the dynamometer output at high current setting for more than a
minute without first turning on the dynamometer water-cooling as this may
result in permanent damage to the dynamometer.
13.
14.
15.
Fill in the calibration details in the centre fields for any equipment used
The Dyno Ctrl Op channel is now calibrated.
2.
3.
4.
5.
Select the Test ControlDemand Control box. Change to Position control mode
on the throttle. Enter a throttle demand of 0%.
June 2009
55
TEXCEL SOFTWARE
6.
Press Accept; confirm the checkpoint taken is within tolerance (i.e. the % FS Error
indicator is green not red, the overall Check Cal Status should indicate Pass). For
a checkpoint to pass, the error between the current signal input and the Engineering
Value entered must not exceed the Permitted % Tolerance set for the channel.
Note that the percentage readings are based on the engineering range of the channel
(i.e. the difference between the Eng Unit Minimum and Eng Unit Maximum).
7.
8.
Select the Test ControlDemand Control box. Enter a throttle demand of 10%.
9.
10.
Repeat this process for 10% steps to 100% fully open throttle.
11.
To check for hysteresis, repeat the process in the opposite direction, decreasing
steps of 10% from 100% - fully open to 0% - fully closed.
12.
To check for repeatability and hysteresis over larger steps, enter checkpoints of 10%,
40%, 10%, 40% and 10%. Repeat for checkpoints 40%, 70% and 40%.
All check calibration points should pass the tolerance check as shown in the following Figure
3-20. Note that where a printer is interfaced to the PC (local or network connection), this
calibration certificate can be printed for future reference.
56
3.6
IM 1347/1 ISSUE 5
Select the required channel by clicking the Channel Select button and choosing it
from the channel select list box. When the channel has been selected, its current
configuration is displayed. The hardware address field is used to identify where it is
connected and the current value field shows its current state. (The required channel
can also be determined from the UtilitiesSensor Connection List option).
2.
Set the channel name by clicking in the Channel name text box and typing in the
new name. This is the display name of the channel selected.
3.
Set the required sense by clicking either the Inverted or Normal buttons. Texcel
digital inputs are normally defined to be On (or true) when supplied with 24volts. If
an input is supplied with 24volts for its Off (or false) state, the sense should be set to
Inverted.
4.
End the configuration by either selecting a new channel or clicking the Exit button.
June 2009
57
TEXCEL SOFTWARE
3.7
1.
Select the required channel by clicking the Channel Select button and choosing it
from the channel select list box. When the channel has been selected, its current
configuration is displayed. The hardware address field is used to identify where it is
connected and the current value buttons show its current state. They may be used to
force a required state.
2.
Set the channel name by clicking in the Channel name text box and typing in the
new name. This is only used for display purposes.
3.
Set the required sense by clicking either the Inverted or Normal buttons. Texcel
digital outputs are voltage free relay contacts with the wipers commoned. When the
sense is configured as Normal the relay is energised for the On (or true) sate. If an
output is configured as Inverted the relay is energised for the Off (or false) state.
Generally, the controllers can be configured to control any parameter provided that
There is a direct relationship between the actuator and the controlled value.
An analogue output card (normally a Froude Hofmann SBB / PMF / MFIO or DX100 board) is
required to use the external controllers.
58
IM 1347/1 ISSUE 5
Outlet Channel
Demand
Actuator
Engine
Pipe Temp
Loss
Control
June 2009
59
TEXCEL SOFTWARE
Example: A normal control action results in the controlled parameters value increasing as the
actuators output is increased from minimum to maximum (a resistive heater will
generate more heat as the current flowing through it increases). If the engine coolant
control valve is normal closed and requires an input to open it, then as the controller
output increases the engine temperature will decrease, thus requiring the controller to
have a reverse control action.
Note
The controllers work in the engineering units defined for the servo feedback channel. If this
channel is configured to measure in Degrees C, the controller demand will be in Degrees C and
the error will be in Degrees C.
The controller coefficients work directly on the error value. A P coefficient of 1.0 can therefore
drive the actuator from fully closed to fully open for a 1 Degree C error.
2.
3.
The first two steps are normally only required when setting up a new controller.
60
IM 1347/1 ISSUE 5
Click the Configure button for the required controller. This will launch the controller
configuration dialog shown below.
Controller coefficients. These numerical entry fields are used to set the controller
performance
Controller variables. These numerical fields display the internal outputs of the
controller.
Analogue Output Details. These text fields identify which analogue output is being used
by the controller.
Controller feedback values. These numeric fields show the current values of the input
channels being used by the controller.
Trend display. This is a configurable 8-channel trend display. By selecting the controller
channels onto it, it can be used to graphically show the relationships between the
feedback channels to help optimise the control.
Control buttons. These buttons are used to start the extra dialogs for configuring the
controller.
June 2009
61
TEXCEL SOFTWARE
Servo Feedback Channel. This must always be configured. This is the primary feedback
loop. If the controller is configured as a single loop controller, then the input measuring the
controlled parameter should be selected, otherwise, for multiple feedback controllers, the
input measuring the value at the servo output should be selected.
Inlet Feedback Channel. This channel should be configured for multiple feedback
controllers where there is a transducer measuring the value at the engine input. It improves
the performance of the controller where there is a large distance between the servo
actuator and the engine and hence a change in value (temperature) between the servo and
the engine. If there is no transducer available, then the channel should be cleared. If this
channel is configured then the Loop One (Inner) Filter Factor should be set to 1.000 to
enable this channel.
Outlet Feedback Channel. This channel must be configured for multiple feedback
controllers where there is another transducer measuring the output of the servo loop. It
should be set to the input that measures the controlled parameter. If this channel is
configured then the Loop Two (Outer) Filter Factor should be set to 1.000 to enable this
channel.
Actuator Feedback Channel. This channel is used for display purposes only. If there is a
channel measuring the position of the servo actuator, this input should be selected. This
enables the correct operation of the actuator to be established by comparing the controller
output and the actuator feedback values.
62
1.
2.
3.
4.
5.
Run the system and optimise the proportional and I Max terms
6.
IM 1347/1 ISSUE 5
The procedure below describes setting a single loop controller with a normal control action
where initially the demand is greater than the feedback value, causing an initial negative error.
It also assumes that the dynamic response of the system is unknown or difficult to measure. If
the dynamic response of the system has been evaluated, it should be possible to directly set
workable coefficients.
June 2009
63
TEXCEL SOFTWARE
Check that as the controller output increases, the rate of change of the servo feedback value
decreases, ultimately causing the servo feedback value to reduce back towards the demanded
value.
The biggest issue with control of engine water temperature is the large overshoot in
temperature when rapidly increasing the engine power or when bringing the engine up to
temperature from cold. This overshoot can be controlled by using the Imax term to effectively
clamp the controller output to limit overshoot.
In order to set Imax it is necessary to run the engine through a number of cycles to establish
what the overshoot is, to do this set Imax to 0.9 and run the engine at suitable power levels to
achieve operating temperatures. Using the trend on the Configure External Controllers Dialog
observe the system response when increasing and decreasing the engine power level and the
resultant engine temperatures. If the temperature does not reach the demanded level when the
engine is running at a power level where it should achieve the demand temperature then the
value of Imax is too low and the output is being clamped too much, increase the value of Imax
until the engine reaches the demanded temperature.
If the temperature exceeds the demanded temperature by more than 2 deg C then the value of
Imax is too large and should be reduced until the engine temperature overshoot is no more
than 2 deg C.
Cycle the engine power levels a number of times to confirm that the overshoot is controlled to
within + 2 deg C, at this stage the amount of undershoot is largely irrelevant however too large
a swing in temperature could cause instability so reduce the P term until the undershoot is no
more than 10 deg C.
Once the temperature overshoot is under control then the P term should be adjusted to achieve
an acceptable undershoot. If the undershoot is too big then the P term value is too large and
should be reduced until the undershoot is less than 2 Deg C. During adjustment of the P Term
it may be necessary to readjust the Imax value to ensure the temperature overshoot is
maintained at no more than + 2 Deg C.
Using this method it is possible to achieve very tight water temperature control without using
the I term, water control systems are slow to respond and it is unlikely the I term will be
required to achieve acceptable levels of control. The most important element of achieving good
control is to not rush the tuning procedure, setup of engine water systems requires time as the
engine should be allowed to settle at different power levels and the temperatures stabilise in
order to observe the trends, attempting to change things too quickly will lead to poor control
setup.
There should now be a reasonably constant controller output and error.
64
IM 1347/1 ISSUE 5
June 2009
65
TEXCEL SOFTWARE
If no other controller is mapped to the output, check each calculated channel. A calculation may
overwrite the engineering value of the output.
If the output from the Texcel system is fluctuating but the Output Value in the Controller
Variables section of the display is constant, this may indicate a problem with the output
electronics or an electrical fault is present. Select the System ConfigurationCalibrate
Analogue OutputsStart Cal option. This will override the demand from the external
controller software module the output is now driven from the calibration page.
Move the output using the Adjust DAC Output bar graph whilst monitoring the output voltage
or current. If the output signal is not stable, select the ExitShutdown the Texcel Controller
then power down.
On Texcel V6 and V8 systems it is possible to select voltage or current output for each external
controller so this setting should be checked. There are no selection links on the PCI hardware
used in V4 Advantage and V10 as these outputs are always in current mode. Observing antistatic precautions, check the link configuration for the appropriate output channel on the
appropriate Sixteen Bit Board (SBB) each of the eight analogue output channels may be
configured for voltage or current output.
Check the wiring to the actuator, where possible, disconnect the control signal from the Texcel
system and drive the actuator with a simulated voltage or current output.
66
IM 1347/1 ISSUE 5
The following figure shows an external controller set-up for a water-cooling module. The output
Water Control Output drives a valve that is calibrated as minimum (zero volts) to give a valve
fully open position this would give maximum cooling (this is also the fail safe position). The
maximum calibration point fully closes the valve (no cooling).
In the Controller Feedback Values section, the Current Demand set-point is 80 C. The
Servo feedback channel Coolant Out Temp is currently 70 C. The Error is therefore 10
C, the controller should reduce cooling to allow the Coolant Out Temp to rise to the set-point.
However, the Current Value reads 0 the valve is fully open full cooling.
The correct remedial action in this case is to change the sign of the Proportional Term, in
this case from 0.02 to 0.02. The following figure shows the result of changing the
Proportional Term. The Output Value now drives to 1 this closes the valve to reduce
cooling. As the valve closes the amount of cooling reduces. The engine must be running of
course to generate the heat required to raise the Coolant Out Temp to the set-point. In some
situations, such as when the engine is idling, the engine does not provide enough heat and the
set-point is never achieved.
To test the controller in this situation, reduce the Current Demand to a set-point below the
current Coolant Out Temp reading. When the set-point is lower than the current Servo
temperature, the Error will be negative; the Output Value should decrease towards zero.
This should open the valve to increasing the cooling to drive the temperature down to the new
set-point.
June 2009
67
TEXCEL SOFTWARE
An Output Channel. These are analogue output channels only and are normally situated
on the SBB board but may also be available on the PMF, DTC or MFIO board types.
A Servo Feedback Channel. The feedback channel may be any type of channel such as
a temperature sensor, any other physically connected sensor input, a calculated channel or
a manual input.
A non-zero Proportional Term. As a rough guide this term is the 1 / Servo Feedback
Channel maximum range. (e.g. if Coolant Out Temp thermocouple has a calibrated range
of 200 C, the initial setting is 0.02)
A positive Integral Term. For actuators or valves the initial value should be at least 100
seconds.
Update Rate should take a positive value, 1 second for an actuator or valve.
A Current Demand set-point. Note that the demand can be set in the System
ConfigurationConfigure External Controllers page or in the External Devices page
of automatic test sequences.
3.8
As each engine / dynamometer will react differently to the PID set-up, an interactive method is
best used to configure these values. Whilst PID re-tuning for each engine / dynamometer
68
IM 1347/1 ISSUE 5
combination maximises the control performance, this is optional - a general set-up is normally
achievable to suit multiple engines of similar response characteristics.
The throttle and the dynamometer have separate sets of coefficients for each control mode.
When a new mode is selected, the current coefficients for that mode are displayed. Position
mode does not require its own set of coefficients as the position of the valve is directly related
to the demand. Power law uses the torque control mode, with the torque demand being
modified as a function of engine speed and hence uses the torque PID coefficients.
The control PIDs are adjusted using the System ConfigurationConfigure Control PIDs
option at supervisor access level.
dt
The control signal forms either the dynamometer's coil current demand (for eddy current
dynamometers) or the dynamometer's outlet valve position demand (for hydraulic
dynamometers). Similarly, the control signal forms the throttle position demand for an
engine control system. Note that Figure 3-29 illustrates a dynamometers control system,
however, the same diagram can be applied to a throttle control system.
June 2009
69
TEXCEL SOFTWARE
3.8.2 Proportional
The simplest form of closed loop feedback control would be to amplify the error by some
negative gain to form the control signal. This type of control is referred to as proportional only
control, where the proportional, P, coefficient is multiplied by the normalised error between the
demand and the feedback.
(demand, in eng units feedback, in eng units) x P
Configured system maximum.
The P coefficient is entered as a gain of between 0 and 99.999, to a resolution of 0.001. A
comparison between the proportional coefficient of the Texcel controller and Froude Hofmann's
previous analogue controllers is given in Figure 3-31.
70
IM 1347/1 ISSUE 5
Coefficient Ranges
Speed Control Mode
Torque Control Mode
Control card
Adjustment
Range
Control card
Adjustment
Range
Controller
Parameter
CD HO/70D
&
CD TO/70B
Proportional
Integral
Differential
TP 8444
TP 8444
TP 8444
VR 3
VR 6
VR 4
0.22 - 22
0 - 0.45 Sec
0 - 1 Sec
TP 8445
TP 8445
TP 8445
VR 3
VR 6
VR 4
0.06 - 5.6
0 - 1.8 Sec
0 - 1 Sec
CD
PMC/70E
Proportional
Integral
Differential
TP 8445
TP 8445
TP 8445
VR 3
VR 6
VR 4
0.06 5.6
0 1.8 S
0 - 1 Sec
TP 8445
TP 8445
TP 8445
VR 3
VR 6
VR 4
0.06 - 5.6
0 - 1.8 Sec
0 - 1 Sec
Texcel 50 &
TM/HO &
TM/EC &
TM/ENG
Proportional
Integral
Differential
E220237
E220237
E220237
RV 19
RV 20
RV 18
0.22 - 22
0 - 0.45 Sec
0 - 1 Sec
E220237
E220237
E220237
RV 13
RV 14
RV 12
0.06 - 5.6
0 - 1.8 Sec
0 - 1 Sec
Texcel
100A
(Dyno only)
Proportional
Integral
E220413
E220413
Prop *
Int *
E220413
E220413
P*
I*
Differential
Proportional
E220413
Digital
Diff *
P*
E220413
Digital
D*
P*
Integral
Digital
I*
Digital
I*
Differential
Digital
D*
0.02 - 32
0.001 1.1
Sec
0. 1 Sec
0.000
99.999
0.000
99.999 Sec
0.000
1.999 Sec
Digital
D*
0.02 - 32
0.001 1.1
Sec
0. 1 Sec
0.000
99.999
0.000
99.999 Sec
0.000
1.999 Sec
Texcel
Note:
3.8.3 Integral
Proportional-only control will always give an error at steady state and this limitation makes it
unusable on its own in the application of dynamometer and throttle control.
This error can be removed by integral action. Whilst an error exists the integral term will
continually increase the control signal in a direction to reduce the error. If a constant error
exists, then the integrator output will ramp to the magnitude of the error in a time set by the
integral coefficient, I. When the error is zero, the output of the integrator will remain constant.
Therefore, the integral term will store a control signal necessary to sustain the steady state
operation of either the dynamometer, or throttle. This is an important consideration when tuning
the controller, particularly when the controlled parameter is currently above or below the
demand.
The I coefficient is entered as an integral time between 0.000 and 99.999 seconds, to a
resolution of 0.001 seconds, and applied to the error according to the following equation.
(Demand, in eng units feedback in eng units) x (0.02) + Accumulation of the
Configured system maximum
( I ) integral terms
A comparison between the integral coefficient of the Texcel controller and Froude Hofmann
previous analogue controllers is also given in the previous Figure 3-31.
June 2009
71
TEXCEL SOFTWARE
3.8.4 Differential
A Proportional and Integral controller will successfully hold the controlled parameter in steady
state. However, if the system is subjected to transients, such as accelerating the engine from
idle, the feedback may well overshoot the demand. This overshoot, particularly in the constant
speed control, may be undesirable.
The transient behaviour can be improved by anticipation of the required control signal based on
the rate of change of the error. Given such information, the control signal may be modified to
prevent the overshoots mentioned.
The 'differential', or D, term is based on the rate of change of the error, or the derivative of the
error, and is summed with the result of the proportional and integral terms. If, for example, the
feedback changes by a linear ramp, then the output of the differential term will be constant.
The D coefficient is entered as a gain of between 0.000 and 99.999, where a gain of 99.999 is
equivalent to a differential time of 1.99998 seconds. The differential term is applied to the
control signal using the equation.
72
IM 1347/1 ISSUE 5
When the controlled parameter is approaching the demanded value, the error will result in a
positive' control signal due to the proportional term. However, the rate of change of the error
will result in a negative' control signal due to the differential term.
The two terms will therefore oppose each other; hence the control signal will be reduced
allowing the feedback to smoothly approach the demand level. If the controlled parameter is
moving beyond the demanded value, the proportional term will now produce a negative'
control signal. However, the differential term will continue to produce a negative' control
signal, thus the two terms combine to reinforce the control signal in a direction to reduce the
error. Consequently, the effect of the differential term is to reduce overshoots or oscillations,
June 2009
73
TEXCEL SOFTWARE
A comparison of the differential coefficient of the Texcel controller to the differential time in
Froude Hofmanns previous analogue controllers is given in the previous Figure 3-31.
74
IM 1347/1 ISSUE 5
3.8.4.1 Filter
This field is maintained for backward compatibility only, the Filter factor has been removed
in Texcel software version 6.30 onwards.
2.
3.
2.
3.
Enter 2.0
June 2009
75
TEXCEL SOFTWARE
adjusting other, less stable control modes. It is therefore recommended that the Throttle
Position, Dynamometer Speed control mode PIDs are adjusted first followed by the Throttle
Position, Dynamometer - Torque and Throttle Speed, Dynamometer - Position control
mode PIDs. The remaining PID coefficient tables may be adjusted in any order.
The required control mode is selected by pressing the Position, Speed, Torque, Power law or
the MAP mode selection buttons on the control panel as appropriate. If attempting to select a
control mode such that the resulting control mode pairing would form an invalid mode pairing,
then the selection is inhibited.
Before commencing PID tuning, it is necessary to ensure that the throttle and dynamometer
servo loops are correctly tuned. Particular care should be taken to ensure that the maximum
DAC range is used for the dynamometer and throttle demands and that the maximum ADC
range is used for the throttle/dynamometer position feedbacks and torque measurement.
Using less than 80% of the available range will reduce system performance and the necessary
hardware and calibration modifications should be made before tuning commences.
The connection between the throttle actuator and engine throttle system should be as rigid as
possible. Any backlash or dead-bands in the connection will result in poor throttle control
performance.
The hydraulic dynamometer outlet valve servo loop should be tuned for minimum rise time with
10% overshoot.
76
The larger the flow of water through the dynamometer, the faster the torque absorbed by
the machine will change when the outlet valve position changes. This has the effect of
increasing the gain of the control system.
The dynamometer will have a greater susceptibility to instabilities at larger water flows.
Lower water flow rates through the dynamometer can have the effect of dampening the
response of the machine. However, if the machine is absorbing high powers then the outlet
water temperature may increase above the maximum limit of 60 Celsius (140 F).
IM 1347/1 ISSUE 5
The dynamometer will become less stable as the outlet valve operates around 30%.
However, the torque change response of the dynamometer will be extremely fast when the
outlet valve is operating in the region below 30%.
The torque absorbed by the dynamometer will change very little for an outlet valve position
of between 90% and 100% so the inlet valve should be set to avoid the outlet valve
operating in this region.
If the dynamometer is required to absorb a high torque at a low speed then the machine will
require a high water fill within the casing assembly. This will require a high flow of water
into the machine and high outlet valve angles of between 70% and 80%.
Generally, the outlet valve will give satisfactory control between 30% and 80%. Use the
inlet valve control to set an appropriate inlet valve demand that will allow the outlet valve to
operate in this region. The inlet valve demand and current inlet valve position will be shown
on the main instrumentation screen.
3.00
Integral
4.00
Differential
0.00
Initial tuning should be performed with the throttle in position mode and the dynamometer in the
desired control mode. The dynamometer / throttle demands should be adjusted to operate the
engine at approximately 25% of its rated speed / torque.
For hydraulic dynamometers, adjust the inlet water flow to ensure that the dynamometer outlet
valve is operating around 30% closed. It should be noted that for optimum performance the
outlet valve should be operated between 30% and 80% closed and necessary adjustments
should be made to the inlet water to maintain this range.
From the initial settings increase the Proportional coefficient in 10% steps, until the
system starts to become unstable. Reduce the Proportional coefficient until stability
returns.
2.
3.
Increase the dynamometer demand by approximately 10% and ensure that steady
state operation is still present at the new set-point. If the control is not stable at the
new set-point, reduce the Proportional coefficient until stability returns.
4.
Adjusting the dynamometer demand between the two set-points, reduce the Integral
Time until the steady state settling time is acceptable or steady state control is no
longer achievable. It may be necessary to make minor adjustments to the
Proportional coefficient during this operation.
5.
Adjust the demands until the engine is operating at around 75% of its rated value.
Reduce the Proportional coefficient if necessary to achieve steady state operation.
June 2009
77
TEXCEL SOFTWARE
6.
Check the transient response at the new set-point by applying 10% demand changes.
Trim the P and I terms as necessary to achieve the required performance.
7.
Where optimal steady state performance is required over the entire operating
envelope, it may be necessary, with some engine/dynamometer combinations, to
increase the Proportional coefficient at lower engine speeds.
8.
If large transient demands are applied to the system it may be necessary to increase
the differential gain to minimise overshoots when moving to a new set-point.
Differential gain may also be required to minimise deviations to a disturbance, e.g. a
step change of throttle position.
9.
Increasing the differential gain may require trimming of the Proportional coefficient.
The differential gain is sensitive and can quickly induce instability.
The single control mode settings can be used as a basis for the combined mode PIDs.
1.00
Integral
4.00
Differential
0.00
78
IM 1347/1 ISSUE 5
Reapply the throttle; if the response is still unstable, reduce the proportional coefficient still
further.
Note:
Where a hydraulic dynamometer is used, it is essential for good control that the water
supply to the machine is as specified in the dynamometer instruction manual. Observe
a minimum pressure of 2 bar (30 psi) at the inlet valve when the valve is at its closed
position.
0.6 x K.
T / 2.
T / 8.
Whilst the Ziegler-Nichols method will provide a good starting basis for tuning the PID's, it rarely
provides the ultimate performance that can be achieve through further manual tuning. It should
also be noted that the coefficients provided by this method would only be suitable for the torque
and speed at which the measurements have been taken.
June 2009
79
TEXCEL SOFTWARE
3.8.19.1
Proportional
In steady state, if the proportional gain is too low then the response of the controlled parameter
exhibits a low frequency oscillation. If the proportional gain is too high then the response of the
controlled parameter exhibits a high frequency oscillation. Increasing the gain from a low value
increases the oscillation frequency and reduces its amplitude.
The optimum setting occurs at the point of lowest amplitude; beyond this point any further
increase in gain will result in the oscillation frequency remaining constant but with increasing
amplitude.
80
IM 1347/1 ISSUE 5
Under transient conditions, too low a proportional gain will allow large overshoots. A higher
proportional gain will reduce the overshoot, but too high a gain will cause ringing'. Increasing
the proportional gain enhances the accuracy of the controlled parameter with respect to the
demand, but will lead to instability if too high. Typical frequencies of oscillation are detailed
below.
EQUIPMENT
Throttle Actuator
Large F type and AG
type Dynamometers
Small F type
Dynamometers
PROPORTIONAL GAIN
TOO HIGH
0.2 to 0.5 Hz
>1 Hz
0.5 to 1 Hz
>2 to 4 Hz
< 1 Hz
>5 to 7 Hz
The proportional coefficient is entered via the PID configuration pages as a gain of between
0.000 and 99.999. The P coefficient should be increased in steps of between 1.00 and 5.00
until the higher frequency oscillations occur, and then reduced until the response is again
stable.
It will not normally be possible to find a P coefficient that does not lead to either high frequency
oscillations or excessive low frequency oscillations. In these circumstances choose a gain that
provides the minimum of high frequency oscillations, and continue by adjusting the differential,
D, coefficient. It may be possible to increase the P coefficient after adjusting the D coefficient.
If a water inlet valve has been fitted to a hydraulic dynamometer increasing or decreasing the
flow of water through the machine may improve the oscillations experienced above. The inlet
valve should be increased or decreased such that the outlet valve operates over the range of
between 30% and 70%. Note the inlet valve setting for the optimum stability against the current
speed, torque and power for the full operating range of the engine.
June 2009
81
TEXCEL SOFTWARE
3.8.19.2
Differential
Generally, increasing the differential coefficient will reduce the magnitude of the deviation
experienced by the controlled parameter, with respect to the demand, in response to a sudden
change in the engine's load output. For example, the deviation from the demanded speed
observed when the engine's throttle is suddenly opened. This coefficient will also reduce steady
state oscillations. The differential coefficient has the undesired side effect of amplifying noise
and ripple in the feedback signal, often contributing to instability. If the gain is set too high,
instability will ensue.
Note:
The proportional and differential terms are used to limit the deviation of the controlled
parameter with respect to the demand. However, the integral term determines the time
taken for the controlled parameter to return to the demanded value.
The differential coefficient is entered via the PID configuration page as a gain of between 0.000
and 99.999. To set the differential coefficient, establish the dynamometer in steady state control
and then move the throttle quickly in a direction to increase the engine's power output by
between 20% and 25%. Note the deviation of the controlled parameter with respect to the
demand. Increase the differential coefficient in steps of between 0.10 and 0.25 until this
deviation is reduced to a minimum or until the response is too oscillatory. In the latter case, the
D coefficient will have to be reduced to restore stability. If the deviation is still not satisfactory,
return to the proportional, P, coefficient. With the increased D coefficient it should be possible
to increase the P coefficient without inducing the higher frequency oscillations noted during
earlier adjustment of this coefficient.
.
If a water inlet valve has been fitted to a hydraulic dynamometer, optimum control of the
deviation may be realised by increasing the flow of water through the machine.
82
3.8.19.3
IM 1347/1 ISSUE 5
Integral
In general, the lower the integral time constant, I, the faster the controlled parameter will return
to the demanded value after a disturbance, for example a change in the load output from the
engine. If the integral time is too low then the controlled parameter may become unstable after
a disturbance. The response may, however, be stable at steady state when the adjustment to
the coefficient is made.
The integral coefficient is entered via the PID configuration page as a time between 0.000 and
99.999 seconds. To set the integral coefficient, subject the system to a similar load disturbance
as experienced during the differential coefficient adjustment and note the time taken for the
controlled parameter to return to the demanded value. Decrease the integral time coefficient in
steps of between 0.05 and 0.10 until the recovery time is reduced to a minimum, or until the
response is too oscillatory. In the latter case, the I coefficient will have to be increased to
restore stability.
If a water inlet valve has been fitted to a hydraulic dynamometer, the oscillatory response
experienced after a deviation may be damped by decreasing the flow of water through the
machine.
June 2009
83
TEXCEL SOFTWARE
The inlet valve has two modes of operation, in Manual the valve responds directly to a
positional demand entered by the user. In automatic mode the inlet valve responds to a
calculated demand dependent on the inlet valve configuration details as entered below.
1
2
3
4
5
6
7
8
9
Figure 3-40 Inlet valve configuration channels
84
Item
Number
Name
Usage
IV Interlock Speed
IV Interlock Position
IV Min X
This is the speed below which the inlet valve will be set
to IV Minimum Position
IV Max X
IV Maximum Position
IM 1347/1 ISSUE 5
For day-to-day operation it is only necessary to have items 1 & 2 from the above table on
the screen. This will enable the user to switch the inlet valve between manual and
automatic mode and to enter the inlet valve demand.
Consideration should be given to the following notes when configuring the automatic
control of dynamometer inlet valve:
Small changes in the inlet valve position when the valve is near its closed position will have
a considerable effect on the torque absorbed by the dynamometer. Therefore, if the inlet
valve is hunting, due to a slight oscillation in the scheduling parameter, this will lead
directly to an unstable performance of the dynamometer. To minimise this effect chose a
parameter that is likely to be stable at steady state.
June 2009
85
TEXCEL SOFTWARE
It may be beneficial to schedule the inlet valve such that it will achieve its fully open position
well before the engine reaches its maximum setting. For the example given previously, the
maximum speed for the purposes of inlet valve control is 6000 rpm. The maximum speed of
the engine may be 8000 rpm for example so in this situation the maximum inlet valve
position is reached well before maximum engine speed.
The inlet valve will open to the minimum demand immediately after the speed of the
dynamometer reaches the minimum speed interlock. This may cause a sudden load to be
applied by the dynamometer that may stall the engine. The choice of minimum inlet valve
position should be made carefully to prevent this.
Consider the throttle in the speed control mode and the dynamometer in the
torque control mode. If the torque absorbed by the dynamometer is lower
than the demand, then the PID control loop will cause the dynamometer to
increase its load. This increase in torque will cause the engine speed to
decrease and the throttles PID control loop will open the throttle to
compensate. The increase in the throttle position will increase the torque
produce by the engine that may now be greater than that demanded from by
dynamometer. The dynamometers PID control loop would then decrease the
absorbed torque to compensate. Experience has shown that system would
become unstable if the PID coefficients found suitable for the single control
mode loops, i.e. Speed - Position and Position Torque, were entered for
this control mode pair.
To allow Coupled control modes to operate without the need to readjust the PID coefficients
separate coefficient tables are provided for each of the valid control mode pairs. The following
notes should be considered when adjusting the PID coefficients:
Dynamometer Speed Control Mode The initial setting of the P coefficient will be
approximately 30% of the coefficient found suitable for the Position Speed control mode.
The I coefficient will be approximately double and the D coefficient will be approximately
50%.
Dynamometer Torque Control Mode The initial setting of the P coefficient will be
approximately 50% of the coefficient found suitable for the Position Torque control
mode. The I and D coefficients will be approximately the same.
The dynamometer will be capable of changing its load faster than the throttle actuator can
operate. This will generally mean that the coefficients of the throttle PIDs will be lower.
Generally, the P coefficient of the throttle control loop will be 30% of the corresponding P
coefficient of the dynamometer control loop.
Instabilities induced by increasing the coefficients of one control loop in the control mode
pair may be compensated by adjusting the coefficients of the other control loop in the pair.
For example:
86
IM 1347/1 ISSUE 5
The ideal final set up of the PID coefficients will give approximately equal weight to both
control loops. The coefficients of one control loop should not be reduced to compensate for
coefficients that are too high in the other control loop of the control mode pair.
For example:
Ensure the engine has been warmed to its normal operating temperature, and run the
engine at approximately one third of its rated power and speed.
Adjust the dynamometer speed control mode first, starting with the P coefficient. Increase
the coefficient until the response exhibits higher frequency oscillations and then decrease.
Increase the D coefficient to reduce the deviation of the controlled parameter from the
demanded value following a disturbance. The D coefficient can also be used to improve
any steady state oscillations found when adjusting the P coefficient, return to the P
coefficient as necessary.
Check and adjust the P and D coefficients at higher powers and speeds, and re-check the
controllers response at the lower power and speed levels afterwards.
For hydraulic dynamometers, increasing the inlet valve position will allow the dynamometer
to respond faster. Decreasing the inlet valve position will dampen the dynamometers
response. Where an inlet valve has been fitted to a hydraulic dynamometer, it can be used
to some considerable effect to improve the quality of the control of the dynamometer.
Decrease the I coefficient to reduce the time taken for the controlled parameter to return to
the demanded value after a disturbance.
When the dynamometer speed control mode has been successfully adjusted, repeat the
procedure for the dynamometer torque control mode and then the throttle speed control.
The effect of increasing the each of the parameters is given in the following table.
EFFECT
PARAMETER
Steady State
Stability
Over-shoot
Settling Time
Oscillations
Improve
Improve
Little Effect
Increase
Little Effect
Little Effect
Improve
Little Effect
Improve
Improve
Little Effect
Improve
Experience has shown the following PID coefficients are be suitable as initial settings.
Variations to these settings are normally in the range of 50% of the values shown.
June 2009
87
TEXCEL SOFTWARE
3.9
When Edit Channel Mapping is selected from the System Configuration menu, the
following dialog box is displayed:
88
IM 1347/1 ISSUE 5
The three buttons Analogue, Digital Input, and Digital Output control which section of the
Channel Mapping you are currently editing. Clicking on one of these buttons will change the
lists of information accessible through the Mapping Channel and Channel Name fields.
The Mapping Channel field displays the System Name from the Channel Mapping section
i.e. the physical channel name that is recognised by the controller. Clicking on this field will
display a drop-down list containing all the user configurable Mapping Channels in the currently
selected section (Analogue, Digital Input or Digital Output).
The Channel Name field displays the User Name of the selected channel i.e. the display
name that is shown on dials, bar graphs and digital displays within the Texcel system. Clicking
on this field will display the Channel Select dialog this dialog will contain all channels
relevant to the selected section (Analogue, Digital Input or Digital Output).
The Address field displays the hardware address of the selected Channel Name. If no
Channel Name is selected the Address field is blank.
The Description field will display a brief explanation of the purpose of the currently selected
Mapping Channel.
Clicking the Default button will assign a default channel to the currently selected Mapping
Channel these defaults are based on the most common configurations for the Mapping
Channel. Clicking the Default All button will assign default channels to all Mapping
Channels in the selected section (Analogue, Digital Input or Digital Output).
2.
3.
4.
5.
Double-click on Sequencer 1.
6.
7.
8.
9.
When using the Test Sequence Editor, the selected Digital Output channel will appear in the
Stage Digital Outputs dialog, and can be controlled from within the Sequence.
June 2009
89
TEXCEL SOFTWARE
4.1
the operational aspects including calibration of the AVL Fuel weigher are covered in
IM1346 Texcel Software Operator's Guide.
; 9600 baud
; add checksum
; V24 RS232C
; short out hardware handshake (i.e. 3 line interface)
90
Signal
TxD
RxD
Gnd
Gate
Wire
colour
GRN
YEL
BRN
WHT
SBB Port 0
/dev/tty5
C5
A5
A3
Not Connected
SBB Port 1
/dev/tty4
C2
A2
C3
Not Connected
IM 1347/1 ISSUE 5
Colour
RED
GREEN
YELLOW
RED
RED
RED
GREEN
Indication
ON=Measuring/Calibrating/Busy
OFF=Ready
ON=No errors
FLASH=In error state
OFF=System error
ON=Auto or Check Cal active FLASH= Auto Cal Drain Req.
ON=Measure active
OFF=No measure active
Not Used
ON=Fill valve open
OFF=Valve Closed
ON=bypass open
OFF=Bypass closed
Category
Analogue
Analogue
Analogue
Analogue
Channel Name
Fuel Weight
Fuel Mass Flow Rate
Current Fuel Weight
Fuel Filling State
Address
SYSV:0:AD:00
SYSV:0:AD:01
SYSV:0:AD:07
SYSV:0:AD:08
June 2009
BMEP
Delivery Rate
= 2 * (FuelMassFlowRateInKg/h) * 10^6 /
(NoOfCylinders x fuelSpecificGravity x Speed x 60)
[Units = mm3 per stroke]
SFC
= (FuelMassFlowRateInKg/h) x consumptionFactor1 /
(Speed x Torque x consumptionFactor2)
[Units = KgH]
[Factor1 = 9.5493e6 (Torque in Nm) or 5252 (Torque in lb/hr) ]
[Factor2 = 1 gram per kWh]
91
TEXCEL SOFTWARE
Note:
4.2
Variables such as fuel specific gravity, engine capacity, number of cylinders and
consumption factors can either be declared as local variables within the calculation
initialised with constant values or be derived from power unit entries. Channels that are
configured with channel names that match a power unit entry exactly will be updated
with the power unit value when a power unit is loaded (at system start-up or when
running a test).
4.3
the operational aspects including calibration of the AVL Smoke Meter are covered in
IM1346 Texcel Software Operator's Guide.
92
SBB
SBB
SBB
SBB
SBB
SBB
SBB
SBB
SBB
SBB
SBB
SBB
SBB
SBB
SBB
SBB
SBB
SBB
SBB
SBB
Board Channel
DO 00
DO 01
DO 02
DO 03
DO 04
DO 05
DO 06
DO 07
Board Channel
DI 00
DI 01
DI 02
DI 03
DI 04
DI 05
DI 06
DI 07
DI 08
DI 09
Note:
4.4
IM 1347/1 ISSUE 5
AVL 735 Fuel Mass Flow Meter & AVL 753 Fuel Temperature Controller
Modules
This section describes the diagnostic facilities available for use with the AVL 735 fuel mass flow
meter and the AVL 753 fuel-conditioning module. For day-to-day operation of these devices
please refer to IM1346 Texcel Software Operators guide.
As the operation of the fuel measurement and fuel temperature conditioning modules are linked
then the diagnostics and maintenance operations are accessed from the same menu item and
dialogs for both devices.
COM 1
COM 1
AVL 735
Fuel Mass Flow Meter
AVL PC Based
Application
Texcel
User Interface Processor (PC)
COM 2
COM 2
Texcel User
Interface Application
COM 1
COM 1
AVL 753
Fuel Temperature
Controller
Texcel Based
Drivers (x2)
Texcel
Real-Time Processor (RTP)
COM 2
COM 2
June 2009
93
TEXCEL SOFTWARE
Note that each AVL device has two communications ports (serial RS232) each fed into the two
computer systems that comprise the Texcel Control System. Additional signalling between the
AVL devices co-ordinates automatic venting (if selected).
The Texcel system emergency stop safety shutdown chain is linked to the AVL753 Fuel
Temperature controller unit. On an emergency stop condition, both AVL devices will return to
failsafe condition. The Fuel Temperature Controller will turn off all pumps and stop fuel
circulation to the engine. The Fuel Mass Flow Meter is powered by the Fuel Temperature
Controller, on an emergency stop condition the power is removed isolating the fuel inlet feed to
both devices and releasing pressure from the engine circuit via the vent line.
Note:
94
It is strongly recommended by AVL that each AVL fuel device be fed with an interlock
indicating the availability of both fuel and cooling water. This signal can normally be
derived from the customers services. The loss of either fuel or water must result in the
loss of this status interlock to the AVL devices as a protection against running the fuel
unit pumps in out of fuel and / or water condition. There are integral flow switches but
these should not be solely relied upon to prevent damage to the pumps.
IM 1347/1 ISSUE 5
The display is split into two sections the left column displays channels from the AVL 735 Fuel
Meter, the centre and right hand side displays channels from the AVL 753 Temperature
Controller. The top part of the display shows temperatures, pressures and operational timers &
counters for internal devices. The lower part of the display indicates the operating state of
internal devices such as pumps, valves and signalling external to the device. Note that
Pump/Valve operation timers/counters have programmable limits to produce warning
messages on the Texcel display. These limits are set using the AVL PC application program in
Maintenance mode.
June 2009
95
TEXCEL SOFTWARE
Description
AVL735 Pump 1 OP
This indicates the fuel meter main internal pump is enabled (but not
necessarily currently running). This signal is normally active for most
operating modes such as measuring (standby), venting, filling and
draining and inactive in pause state.
This indicates the actual fuel pump operation (the AVL735 Pump 1 OP
signal is the enabling signal). The nominal operating current is
approximately 6 amps although this will peak momentarily in excess of 10
amps when the pump starts or stops.
This indicates the pressure developed by the AVL735 Fuel Meter main
pump into the internal pressure accumulator device, this is nominally 6.5
bar when the pump is running.
AVL735 Pump 2 OP
This is the state of the internal fill valve on the main fuel inlet. This valve
opens to maintain the level in the Fuel Meter internal reservoir tank and is
normally triggered when the Tank Level IP is activated.
When this input is active the Fuel Meter internal overflow vessel is full
and the device normally returns an error 15: Tank Overflow. The user
must manually drain the internal overflow vessel using the manual valve
inside the AVL 735 (this is normally connected to the cell fuel dump line).
AVL735 Services OK
This signal is provided externally from the cell fuel delivery system and
chilling water plant. It is recommended that the user provide this signal
(In-Cell day header tank low level switch for example) to indicate that fuel
and cooling water are available. This signal should normally be active
indicating the external interlock is healthy and services are available.
This is the signal from the AVL 753 Temperature Controller to the AVL
735 Flow Meter (via the Sync cable) to trigger venting in both devices if
the Temperature Controller detects bubbles in the fuel for example and
automatic venting takes place. Note the in this situation measurement
mode will be suspended until the venting cycle has competed and this
signal turns off.
This signal driven active by the AVL 735 Flow Meter to inhibit venting by
the AVL 753 Temperature Controller (via the Sync cable). This
condition normally occurs when the AVL 735 Flow Meter is currently not
able to vent. Since the Fuel Meter is the only device connected to the
cell vent line, the AVL 753 Temperature Controller must vent through the
Fuel Meter and must therefore be restricted to do so if the Fuel Meter is
currently busy or in fault state (e.g. in overflow error state).
This signal indicates the state of the primary engine circuit flow switch.
This signal is normally active when the AVL753 Fuel Pump is on.
AVL753 No Bubbles In
Fuel
This signal is active when the engine fuel circuit is clear of air. Since the
signal is momentary, the error indication 9: Bubbles In Fuel is triggered
and latched by this input until venting is either manually or automatically
activated.
96
IM 1347/1 ISSUE 5
This signal is provided externally from the cell fuel delivery system and
chilling water plant and should be driven from the same signal as that
connected to the Fuel Meter AVL735 Services OK signal. If this signal
becomes inactive (the interlock is broken), the fuel pump and valves turn
off and the device enters the error state 3: No Fuel
This signal is driven to follow the state of the Texcel shutdown chain. If
the Texcel system shuts down, on a shutdown alarm condition for
example, this interlock is broken and the AVL fuel system enters the
emergency shutdown state. In this condition power is removed from the
AVL 735 Fuel Meter and all its internal devices enter fail-safe pressure
is relieved from the fuel circuit. The AVL753 Temperature Controller
stops the fuel and coolant pumps and reverts valves to fail-safe.
AVL753 Heating
This signal indicates the heater unit option has been detected
This signal should normally be on if the coolant pump is on. If this signal
turns off for any length of time whilst the coolant pump is still active this
may indicate lack of cooling water or air in the coolant system. This may
result in errors 4: No Cooling Water and 22: Flow Switch Water.
June 2009
97
TEXCEL SOFTWARE
If the AVL PC Program is shut down without releasing control the Texcel system will
not be able to take over control of the device(s). To get out of this condition
it is necessary to re-start the AVL PC Program by pressing the Maintenance
button on the Texcel display and press the Monitor button on the AVL PC
Program for each device.
Note that calibration should only be carried out when accuracy check is out of tolerance in
accordance with the AVL documentation. The calibration unit should be removed at all other
times during normal running to prolong life and accuracy. Calibration including accuracy check
should only be attempted when the local acceleration due to gravity is set using the AVL PC
Program. This can normally be derived from local meteorological organisations.
Where accurate latitude can be determined by GPS for example and the customer site is
relatively close to sea level, the following formula can be used as an approximation (although
this will compromise calibration accuracy);
By the International Gravity Formula,
g = 978.0495 [1 + 0.0052892 sin2(p) - 0.0000073 sin2 (2p)]
2
(The standard value of gravity, is defined as go=980.665 cm/s , this value corresponds closely
to the International Gravity Formula value of g at 45 latitude at sea level).
98
Manual Description
AT1242E_02_Fuel_Temperature_Control.pdf
AT0803E_05_Fuel_Mass_Flow_Meter.pdf
AT1416E_01_PC_Software_735_753C.pdf
4.5
IM 1347/1 ISSUE 5
June 2009
99
TEXCEL SOFTWARE
Ensure the Reconnect at Logon box is selected which ensures the drive will always be
mapped when the Texcel UIP is started.
Press OK to map the drive and using explorer ensure that the calibration tool drive is
accessible from the Texcel UIP.
100
4.6
IM 1347/1 ISSUE 5
The Texcel electronic throttle control is achieved by simulating one or more of the ECU inputs
normally received from the in vehicle accelerator pedal. The vehicle accelerator pedal normally
consists of a number of potentiometers arranged to provide feedback voltages proportional to the
accelerator pedal position.
The most common arrangement for the pedal position sensor is to provide two pedal position
feedback voltages, one which increases in voltage and one which decreases in voltage when the
accelerator pedal is moved between the 0% and 100% positions. These are commonly referred to as
track 1 and track 2 and are known as APPS (accelerator pedal position sensor) inputs.
There are some accelerator pedals which have a third output however this is normally only used by
the ECU in the event of a failure of pedal position inputs 1 or 2. In most cases it is therefore not
necessary to simulate this signal. Texcel is provided as standard to simulate the signals from pedal
position sensor tracks 1 and 2. If this third pedal position signal (track 3) is required please contact
Froude Hofmann for the necessary hardware and software modifications.
The simulated pedal position feedbacks can then be injected into the engine harness, usually at the
accelerator pedal connector, to simulate the in vehicle pedal position signals.
Texcel is supplied pre configured to drive two analogue voltages in the range 0 to +10 Volts DC. This
is the default voltage output, the voltage range can be changed using engine power unit variables, if
the signal type needs to be changed (i.e. to 4 to 20 mA) then please contact Froude Hofmann for
details of changing the buffer module configuration.
These analogue outputs are each controlled by a software external controller configured to use the
output of a throttle scaling calculation as its demand input.
The throttle scaling calculations derive their input parameters from the engine power unit. In this way
any throttle configuration and scaling requirements become engine specific. This means there is no
requirement to modify calculations or recalibrate the analogue signals to change throttle configuration,
merely modify the entries in the engine power unit file.
The Texcel analogue outputs and buffer modules are calibrated to provide a 0 to +10 Volts signal for
a throttle demand of 0 to 100%. Do not adjust the calibration of these outputs; any change in the
voltages required is achieved using the engine power unit variables as shown below.
4.6.2 Configuration of the Engine Power Unit to use Electronic Throttle Control.
In order to simulate the accelerator pedal Texcel needs to know the feedback voltages produced by
the in vehicle pedal position sensors when the accelerator pedal is at 0% and 100% respectively.
These voltages are stored in the engine power unit in four variables contained on the User Data tab of
the engine power unit file as shown in figure 4-4 below.
June 2009
101
TEXCEL SOFTWARE
When the engine power unit is selected using the Identify Test menu option then the electronic throttle
will be correctly configured for that engine. The values set in these variables in the default.pun power
unit file will set the electronic throttle configuration on bootup.
Each of these four variables will require modification to match the respective feedback voltages from
the accelerator pedal position sensor,
ThrotT1MinVolts
ThrotT1MaxVolts
ThrotT2MinVolts
ThrotT2MinVolts
102
Configure the power unit variables for the pedal voltages required.
IM 1347/1 ISSUE 5
Using the Identify Test menu option select the engine power unit file for the engine on test.
Monitor the simulated accelerator pedal position inputs, this can be done using a voltmeter on
the output of the buffer modules but is best achieved using an ECU calibration tool which
shows the actual value of the accelerator pedal position ECU inputs. If using an ECU
calibration tool then it may be necessary to have the engine ignition turned on in order to
energise the ECU inputs and outputs.
With the Texcel in Idle the simulated accelerator pedal position should read zero (or the buffer
output voltage should equal the value set for ThrotT1MinVolts in the engine power unit file).
Select Throttle Position mode, put the Texcel into Run mode and rotate the throttle demand
encoder fully anticlockwise. The simulated accelerator pedal position should read zero (or the
buffer output voltage should equal the value set for ThrotT1MinVolts in the engine power unit
file).
Rotate the throttle demand encoder fully clockwise. The simulated accelerator pedal position
should now read 100% (or the buffer output voltage should equal the value set for
ThrotT1MaxVolts in the engine power unit file).
Press the Texcel Stop button, confirm that the simulated accelerator pedal position returns to
zero (buffer output voltage is now equal to the value set for ThrotT1MinVolts in the engine
power unit file).
Repeat the above tests for buffer module 2 if required, noting that the voltages will be those
stored in the variables ThrotT2MinVolts and ThrotT2MaxVolts.
June 2009
103
TEXCEL SOFTWARE
ACCESS LEVELS
5 ACCESS LEVELS
The Texcel system is supplied with five access levels, four of these levels are made available
to the user with the fifth being reserved for Froude Hofmann use.
Of the four levels three have user definable passwords, which can be used to prevent
unauthorised modifications to test procedures and system configurations. The default
password, which the Texcel system is shipped with are shown below, it is recommended these
passwords be changed if required.
5.1
Shortcut
F10
Password
None
required
Team Leader
F11
Team leader
Supervisor
Super
Instrumentation
Ctrl-F10
System
Data Analysis
(Excel Editor)
Froude
Key Icon
System
ALT-F10
Description
Test bed operator. Able to run the system, run
manual tests, select and start tests from
available, pre-configured
Normally used by the test bed engineer or
shift leader. Allows configuration of data for
tests. Modification of the automatic test
schedules, power units, alarms, data loggers.
Normally used by the test bed engineer or
shift supervisor. Allows configuration of data
for tests. Modification of the automatic test
schedules, power units, alarms, data loggers.
Allows access to instrumentation
configuration, calibration and all other utility
functions
Allows access to the normal Excel toolbar to
manipulate the data and produce graphs
Normally not required. (Under control from
Froude Hofmann, this option may be used to
diagnose problems).
5.2
Password
Froude
Texcel
Description
Used for diagnostic investigation only
Used for maintenance and diagnostics
Note:
104
user name and password (and most typed commands) are case sensitive
UTILITIES MENU
IM 1347/1 ISSUE 5
6 UTILITIES MENU
This section deals with the menu option added to the Utilities menu when the user is signed on
at the Instrumentation or above access level. For details of Utilities menu items not covered in
this section please refer to IM1346 Texcel 6.20E operators manual.
6.1
Printer Set-up
This windows dialogue box is used to select and configure the printer to be used for all print
options located within the graphical instrumentation package. Note that this set-up extends to
all pages within the graphical package only, a separate printer set-up is required for all Excel
based editors such as the Power Unit, Test Sequencer, Alarm Set Editors and the Data
Analysis options.
The printer set-up dialogue box is also accessible from pages that allow printout, (such as
System ConfigurationConfigure Control PIDsPrinter Setup).
Settings in this window may be printer specific. Common settings include the paper size,
source and orientation.
The Printer button displays a further dialogue that allows the selection of a printer from those
available to the PC. One or more printers may be locally connected to the PC itself or, where
the PC is interfaced to a company network, a remote printer available as a network resource
(this may require the assistance of a network administrator for correct access permissions for
example). The following figure shows the selected locally connected printer; HP DeskJet
690C.
June 2009
105
TEXCEL SOFTWARE
UTILITIES MENU
Select the StartSettingsPrinters option on the PC. This window will display all
available printers that are interfaced to the PC.
Select Add Printer. A printer may be connected directly to the PC (normally via the
parallel port) or to a host computer via a network (the PC must be connected to a company
network to achieve this).
For a locally connected printer, connect the printer to the parallel port. The PC normally only
has one available parallel port, this will already have the software protection dongle fitted (a
small red or blue connector attached to the back of the PC). The printer lead should be plugged
into the back of the software protection dongle.
Note: a locally connected printer should be left powered on whilst the graphical instrumentation
package is in use.
A network printer requires the PC to be connected to a company network and configured for the
correct login access and permissions in order to access the printer. The printer identification
and host name are required to achieve this.
106
UTILITIES MENU
IM 1347/1 ISSUE 5
Since all printouts from the test sequence editor, power unit editor, alarm editor and data
analysis package are optimised for A4 page output, please confirm this is set in the
StartSettingsPrinters window. Right click the mouse on the newly installed printer and
select Document Defaults select Paper Size to A4 and Paper Source to Automatic. Press
Ok to apply.
Confirm the Texcel graphical instrumentation package is not running (use the ExitExit
the Texcel Display and Return to Windows).
Select the StartSettingsPrinters option on the PC. Click on the printer(s) to remove
then select FileDelete. Close the window using FileClose when complete.
The remaining instructions apply if the Texcel graphical instrumentation package has been run
at least once on the PC.
June 2009
107
TEXCEL SOFTWARE
UTILITIES MENU
Expand the tree by clicking on the + symbols in the left hand pane of the Window to
reveal the PrinterSetup entry if present in the tree
Press the F3 key to search for other occurrences of the registry item KineticaRT. If other
entries are located, repeat the above procedure throughout the registry until all
PrinterSetup entries are deleted.
If a printer is re-installed at a later time the UtilitiesPrinter Setup option should be used to
reselect the new printer for use in the Texcel instrumentation package.
6.2
Windows Explorer
This option starts Windows Explorer for file management. Section 12.5 Further Work
Managing Data. The main use of this option is the management of logged data files.
Consequently, the session starts by logging into the \Data\Results directory of the Texcel
Controller unit.
Warning: Normally, only files in the \Data\Results directory of the Texcel Controller
hard drive should be accessed using Windows Explorer. Directories should
not be removed from the existing tree this may result in the incorrect
operation of the Texcel Controller unit and the possible loss of logged data.
108
UTILITIES MENU
6.3
IM 1347/1 ISSUE 5
VME Monitor
This option is used to diagnose messaging between the Texcel Controller and the PC.
Interpretation of the data in this window normally requires the assistance of Froude Technical
Support.
6.4
Probe
This option is used to debug the Texcel graphical instrumentation package. Interpretation of the
data in this window normally requires the assistance of Froude Technical Support.
June 2009
109
TEXCEL SOFTWARE
DATA MANAGEMENT
7 DATA MANAGEMENT
7.1
There is no requirement to modify files directly on the PC all configuration is performed in the
editors. Software upgrades may backup previous versions of the software on the hard drive; the
active project is stored in the \Froude directory. The storage requirement may increase
slightly if additional graphical objects are added to pages on the graphical instrumentation
package.
7.1.2 The Texcel Controller Unit Configuration and Logged Data Storage
The Texcel controller access the UIP hard disk for all the configuration and data files required
to operate. The RTP files are located in specific directories as follow;
The \Apps sub-directory contains all executable programs that run on the Texcel Controller.
(Note that this directory is only available to the PC for the purposes of software upgrades).
The \Data sub-directory contains all configuration and logged data.
Warning: Normally only files in the \Data\Results directory should be accessed
regularly using file management tools such as Windows Explorer. No other
directories should be added or removed from the existing tree this may
result in the incorrect operation of the Texcel Controller unit and the
possible loss of logged data.
110
DATA MANAGEMENT
IM 1347/1 ISSUE 5
Test results are stored in the \Data\Results directory, the example in the figure above shows
the files generated for a single test.
Data should be regularly moved, archived or deleted from the Texcel UIP disk to prevent
exceeding the hard disk storage space. This can be achieved using the UIP CD-RW drive or by
copying the files to the customers main server using the network.
7.2
June 2009
111
TEXCEL SOFTWARE
DATA MANAGEMENT
Normally, the File Handler application should be auto-started on system restart select Yes.
If the File Handler application is not auto-started it must be run manually. Data transfer will
only occur when the application is running.
Run the File Handler utility by selecting the StartProgramsTexcel Froude File
Handler menu option. The program will run minimised on the Windows NT task bar
7.2.2
112
DATA MANAGEMENT
IM 1347/1 ISSUE 5
To modify the default settings of the File Handler, click on the program icon on the Windows
NT task-bar. If the program icon is absent from the task-bar, run the program first by selecting
the StartProgramsTexcel Froude File Handler.
With the File Handler program window displayed, right click within the central window area to
get the Properties option left click on this (as shown in the following Figure).
When Properties is selected the File Handler Configuration dialogue will be displayed as
shown in the following figures. Each data category is selected by clicking on the Tab area at
the top of the window.
For each data category, the Source Directory should match that of the file to be copied. This
path normally starts with the drive letter of the Texcel UIP hard drive. Note that Test Result
Transfer is internally configured to move files (i.e. delete the files from the source directory on
completion of the copy operation). The Destination Directory should match the associated subdirectory in the tree created initially using Window NT Explorer.
The File Extension should match that of the type of files to be transferred. The default Check
every XXX Secs field is default to 300 seconds; this is normally sufficient for most situations.
June 2009
113
TEXCEL SOFTWARE
DATA MANAGEMENT
114
DATA MANAGEMENT
IM 1347/1 ISSUE 5
The Test Results Transfer option moves all files once copied to the destination. The File
Extension is normally set to the end-of-test file type Fin by default.
June 2009
115
TEXCEL SOFTWARE
DATA MANAGEMENT
Note that the Alarm Transfer and Sequence Transfer categories would be re-configured in a
similar fashion, the Test Result Transfer category would remain unchanged however.
Note:
to disable the transfer of a data category, clear the Source Directory field.
It is recommended to configure the File Handler utility to regularly transfer test results off the
test bed computer to a host computer where available. Since the data analysis package
normally defaults to the results area on the test bed controller unit, it may be necessary to view
previous test results generated by the test bed that have been moved to the host computer.
This can be achieved by creating a shortcut to the appropriate results folder on the host
computer in the test bed results directory.
116
IM 1347/1 ISSUE 5
8.1
Saving Modifications
All data entry is made using the User Interface PC (UIP). There are two types of data entry and
configuration covered in the following sections.
June 2009
117
TEXCEL SOFTWARE
Example 7:
During a running test, when using the Test DataEdit Comment LogAdd option, the
comment entered is written to file when the Ok button is pressed.
Example 8:
When using the AlarmsEdit Active Alarms option, alarm limit modifications are made active
by pressing the Apply or Ok buttons. Note that modifications using this option are volatile
there is no mechanism to record these modifications to file.
Example 9:
When a channel is selected for display on the instrumentation page for example, this channel
begins updating immediately. The modification does not save to file until the main
instrumentation package exits. On restart the channel lists are read from file to regenerate the
display including the modification.
Example 10:
When customising instrumentation pages by selecting and arranging graphical objects, use the
F9 key regularly to save the modifications to the page, particularly when the modifications are
complete. Page customisation is normally time consuming and errors during editing can be
made easily particularly when auto arranging groups of objects (selecting an inappropriate
alignment option for example may lead to unexpected results). The F9 key allows changes to
be saved or the original page prior to modification to be restored.
118
Throttle and dynamometer control mode, demand set-points and output enables revert to
power on defaults (minimum / disabled state).
The value of manual input channels (these revert to the value zero on restart)
The current setting of digital outputs, Ignition, Crank, Pre-heater, etc, all revert to failsafe
mode (normally off or disabled state).
Active measurement mode on ancillary measuring devices (these devices revert to manual
mode)
Current status and alarm messages (alarms are logged to file for re-display under the Data
Analysis package and fault status messages are logged to the UtilitiesSyslog file
however)
8.2
IM 1347/1 ISSUE 5
June 2009
119
TEXCEL SOFTWARE
8.3
The Texcel is supplied with a set of test sequences already configured for running the EURO 3 and
EURO 4 statutory tests. The EURO 3 tests comprise the ESC (European Stationary Cycle) and the
ELR (European Load Response) tests whilst the EURO 4 test is the ETC (European Transient Cycle)
test.
The test sequences are designed such that it is not necessary to edit the tests for each engine to be
tested, each test will request the data required for the test when run. The ESC and ELR test
sequences can be edited if required however the ETC test is stored as a test profile and cannot be
edited using the Texcel Sequence Editor.
The ESC and ELR tests can be performed using a suitable absorb only dynamometer however the
ETC test cycle has motoring phases and can only be performed on a suitable motoring / absorbing
dynamometer.
120
IM 1347/1 ISSUE 5
= float,0
= float,0
= String20, Undefined
These are the two digital outputs, which combine to say which test is being run. These two digitals
must be do13 & do14, as they need to appear on the sequencer digital output table.
DO13 DO14
0
0
1
0
0
1
1
1
Test type
None - resets the dialog
ESC test required
ELR test required
ETC test required
[Channel080]
ChannelType = DigitalOutput
SourceName = TestSelect1
UserName = DO Test Select 1
Address = SBB:00:DO:13
ConnectionPointID = SBB Con-block#1 +A29/-A/C31
June 2009
121
TEXCEL SOFTWARE
Channel081]
ChannelType = DigitalOutput
SourceName = TestSelect2
UserName = DO Test Select 2
Address = SBB:00:DO:14
ConnectionPointID = SBB Con-block#1 +C30/-A/C31
This is the input which continues the test, Note the SYSV address, this is not a physical input it is a
virtual input.
[Channel098]
ChannelType = DigitalInput
SourceName = DITestContinue
UserName = DI test Continue
Address = SYSV:00:DI:16
ConnectionPointID = SBB Con-block#1 +A22/-A/C14
These are the channels the Euro test configuration dialog writes the calculated values into and are
then used by the captured reference mechanism to run the test. These also allow the actual demand
values in the test to be displayed on the screen as these channels will appear in the channel selection
lists.
[Channel179]
ChannelType = SysVarChannel
SourceName = IdleSpeed
UserName = Idle Speed
Address = SYSV:00:VA:25
ScanRate = 20
ConnectionPointID = System Variable
Max = 10000
DecimalPlaces = 0
LogGroup = 1
Units = Rpm
[Channel180]
ChannelType = SysVarChannel
SourceName = SpeedA
UserName = Speed A
Address = SYSV:00:VA:26
ScanRate = 20
ConnectionPointID = System Variable
Max = 10000
DecimalPlaces = 0
LogGroup = 1
Units = Rpm
[Channel181]
ChannelType = SysVarChannel
SourceName = SpeedB
UserName = Speed B
Address = SYSV:00:VA:27
ScanRate = 20
ConnectionPointID = System Variable
Max = 10000
DecimalPlaces = 0
LogGroup = 1
Units = Rpm
122
IM 1347/1 ISSUE 5
[Channel182]
ChannelType = SysVarChannel
SourceName = SpeedC
UserName = Speed C
Address = SYSV:00:VA:28
ScanRate = 20
ConnectionPointID = System Variable
Max = 10000
DecimalPlaces = 0
LogGroup = 1
Units = Rpm
[Channel183]
ChannelType = SysVarChannel
SourceName = UserSpeed
UserName = User Defined Speed
Address = SYSV:00:VA:29
ScanRate = 20
ConnectionPointID = System Variable
Max = 10000
DecimalPlaces = 0
LogGroup = 1
Units = Rpm
[Channel184]
ChannelType = SysVarChannel
SourceName = RefSpeed
UserName = Reference Speed
Address = SYSV:00:VA:30
ScanRate = 20
ConnectionPointID = System Variable
Max = 10000
DecimalPlaces = 0
LogGroup = 1
Units = Rpm
[Channel185]
ChannelType = SysVarChannel
SourceName = TorqueAtIdle
UserName = Torque At Idle Speed
Address = SYSV:00:VA:31
ScanRate = 20
ConnectionPointID = System Variable
Max = 10000
DecimalPlaces = 0
LogGroup = 1
Units = Nm
June 2009
123
TEXCEL SOFTWARE
[Channel186]
ChannelType = SysVarChannel
SourceName = TorqueAtSpeedA
UserName = Torque At Speed A
Address = SYSV:00:VA:32
ScanRate = 20
ConnectionPointID = System Variable
Max = 10000
DecimalPlaces = 0
LogGroup = 1
Units = Nm
[Channel187]
ChannelType = SysVarChannel
SourceName = TorqueAtSpeedB
UserName = Torque At Speed B
Address = SYSV:00:VA:33
ScanRate = 20
ConnectionPointID = System Variable
Max = 10000
DecimalPlaces = 0
LogGroup = 1
Units = Nm
[Channel188]
ChannelType = SysVarChannel
SourceName = TorqueAtSpeedC
UserName = Torque At Speed C
Address = SYSV:00:VA:34
ScanRate = 20
ConnectionPointID = System Variable
Max = 10000
DecimalPlaces = 0
LogGroup = 1
Units = Nm
[Channel189]
ChannelType = SysVarChannel
SourceName = TorqueAtUserSpeed
UserName = Torque At User Speed
Address = SYSV:00:VA:35
ScanRate = 20
ConnectionPointID = System Variable
Max = 10000
DecimalPlaces = 0
LogGroup = 1
Units = Nm
Once the changes have been made it will be necessary to restart the Texcel controller.
124
8.4
IM 1347/1 ISSUE 5
The test sequencer has a number of special functions built in the use of some of these functions relies
on correct system channel configurations which are detailed below.
June 2009
125
TEXCEL SOFTWARE
126
GLOSSARY
IM 1347/1 ISSUE 5
9 GLOSSARY
9.1
General Terms
CPU
Central Processor Unit, the board containing the CPU runs all the software
for the computer system. The Texcel Controller Unit must contain a CPU
board and DTC board (Dyno Throttle Controller) for a minimum system.
DTC
DX100
CAN Distributed I/O module, contains the minimum pulse, analogue and
digital input and output signals to drive a dynamometer, throttle and engine
enabling and monitoring the minimum system.
DTM
Desk-Top Module, the manual control panel in the form of a stand-alone unit
that is normally located on a desk in the operators area or on a shelf inside
the test cell.
Dynamometer
Device for applying torque to a shaft that is normally connected to the unit
under test such as an engine, gearbox or electric motor. These devices are
normally controlled by regulating electrical current (eddy current
dynamometer or electric motor) or water flow (hydraulic dynamometer). The
amount of torque applied is normally measured using a load cell transducer.
ECC
Eight Channel Counter, this board provides pulse input measuring capability
for up to eight separate inputs.
HRC
Load Cell
MFIO
Multi-Function Input Output, this legacy board is retained from earlier Texcel
product hardware revisions and provides the dynamometer and throttle
control, signal conditioning for temperatures, etc for systems that have older
design in cell boxes. Superseded by the improved DTC board (Dyno
Throttle Controller) the MFIO has a similar but reduced I/O capability.
PCI
Pulse pick-up
Device for detecting the proximity of slotted teeth arranged on a gear wheel
or shaft to measure speed of revolution for display and control feed-back
purposes.
PMF
PCI multi function card, this card is used in V4 PLUS,V4 Advantage and
V10 systems. Provides 16 digital Inputs, 16 digital outputs, 8 analogue
outputs and two encoder / pulse input channels.
June 2009
127
TEXCEL SOFTWARE
9.2
GLOSSARY
PSC
Rotary Encoder
RTP
Real Time Processor, the Texcel Controller unit containing the data
acquisition and control cards and software that controls the test cell
equipment.
SBB
Sixteen Bit Board, a module fitted to the Texcel Controller unit used for
optional digital input, output and analogue output signals. Each board also
contains two RS232 serial ports for communication with ancillary measuring
devices or control equipment such as AC/DC Motoring dynamometers.
SCC
TCP
Texcel Control Panel, the manual control panel in the form of a 6U rack
mounted panel with primary control switches and dials.
UIP
User Interface Processor, the personal computer (PC) that is used for user
display and entry using keyboard and mouse.
VME
Versa Module Europe, an industrial I/O bus standard applied in the Texcel
Controller unit. All processor, data acquisition and control boards fitted to
the Texcel V6 & V8 systems conform to this standard.
Button
Click
Control
An item on the screen that is used for interacting with the user interface.
Drop-Down Box A control consisting of a text box and an arrow. The text box contains the
current value for the drop-down box variable. When the arrow or box is
clicked, a list box is displayed, showing the options available for the dropdown box variable. When an item has been selected from the list box, the
list box is made invisible and the drop-down box variable is set to the
selected item.
128
Double Click
Edit Box
A text box that can have the displayed text changed. The box is highlighted
by clicking into it to reveal a text cursor. The keyboard is used to enter
characters and numbers, to apply the entry press the key.
GLOSSARY
IM 1347/1 ISSUE 5
Graphical Object A graphical item used to display or control one element or channel in the
system. A dial is a compound object made up from curves, ticks, textual
labels and numerical value that is used to indicate the current value of an
associated instrumentation channel selected onto it.
Key
List Box
A multi-line text box, with a scroll bar, from which an item is selected by
clicking.
Push-button
Scroll Bar
A control for scrolling through items, which cannot be fully displayed in the
specified area
Text Box
A graphical object for displaying text that cannot be changed by the user.
June 2009
129
TEXCEL SOFTWARE
SUPPORT DATA
10 SUPPORT DATA
Information in this section is for reference purposes only.
130
SUPPORT DATA
IM 1347/1 ISSUE 5
June 2009
131
TEXCEL SOFTWARE
132
SUPPORT DATA
SUPPORT DATA
IM 1347/1 ISSUE 5
June 2009
133
TEXCEL SOFTWARE
134
SUPPORT DATA
SUPPORT DATA
June 2009
IM 1347/1 ISSUE 5
135
TEXCEL SOFTWARE
SUPPORT DATA
136
SUPPORT DATA
June 2009
IM 1347/1 ISSUE 5
137
TEXCEL SOFTWARE
138
SUPPORT DATA
SUPPORT DATA
IM 1347/1 ISSUE 5
25 Way D Type
1
2
3
4
5
6
7
8
9
CD
RxD
TxD
DTR
Gnd
DSR
RTS
CTS
RI
CD
RxD
TxD
DTR
Gnd
DSR
RTS
CTS
RI
----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
8
3
2
20
7
6
4
5
22
Controller
PC display
Number Of Channels
Per Board.
16, each with 4 wire transducer interface, (mixed input types allowed).
Thermocouple Inputs
Types K, J, R, S, T, E.
PRT Inputs
Strain Gauge
(Pressure) Inputs
Non-Linear Inputs
Cold Junction
Isolation
June 2009
139
TEXCEL SOFTWARE
SUPPORT DATA
Input Filter
8Hz.
Diagnostic
Number Of Channels
16, each with 4 wire transducer interface, (mixed input types allowed).
Thermocouple Inputs
Types K, J, R, S, T, E.
PRT Inputs
Strain Gauge
(Pressure) Inputs
Non-Linear Inputs
Cold Junction
Isolation
Input Filter
10 Hz Low pass.
Diagnostic
Number Of Channels
Per Board
AC Type Input
TTL Input
100KHz max
100KHz max
Open Collector, 30KHz max. with 1K5 Ohm load to 15V dc. Mark / Space
ratio - 3:1.
Diagnostic
140
SUPPORT DATA
IM 1347/1 ISSUE 5
Number Of Channels
Per Board
AC Type Input
TTL Input
100KHz max
Encoder Inputs
Open Collector, 30KHz max. with 1K5 Ohm load to 15V dc. Mark / Space
ratio - 3:1.
Number Of Channels
Per Board
16 off Digital Inputs, 16 off Digital Outputs, 8 off Analogue Outputs, 2 off
Serial Communications Ports.
Digital Inputs
0V to 2V dc.
Digital Outputs
Analogue Outputs
Serial Communication
Port
RS 232 using TxD, RxD, RTS and CTS only at 9600 baud.
Number Of Channels
16 off Digital Inputs, 16 off Digital Outputs, 8 off Analogue Outputs, 2 off
Encoder inputs, 1 off pulse input. .
Digital Inputs
Opto Isolated, current Sinking, 5K6 Ohms Input Impedance +12 to + 24V
input range
0V to 2V dc.
Digital Outputs
Analogue Outputs
June 2009
141
TEXCEL SOFTWARE
SUPPORT DATA
Encoder Inputs
Pulse input
Number Of Channels
16 off Digital Inputs, 12 off Digital Outputs, 4 off Analogue Outputs, 2 off
CAN channels, 4 off Pulse input. .
Digital Inputs
Digital Outputs
Analogue Outputs
Pulse input
250mV to 50V AC, 3Hz to 20kHz (2V AC) or 200kHz (25V AC)
5V or 24V DC, 0Hz to 400kHz 3 channels
10.2.10
Servo Circuits
Number of servos
Drive Current
100mA
Feed-back Potentiometer
1K.Ohm
Excitation Voltage
10V
EC Dynamometer Circuit
Type
Current
Current
7.5 Amps
Type
Changeover contact
Rating
10.2.11
142
SUPPORT DATA
10.2.12
IM 1347/1 ISSUE 5
Number of channels
Sensor Connection
Pressure Sensor
Coupling
Loom length
10.2.13
Environment
Power Requirement
Outputs
Refer to drawing E320114A sheets 001 and 002 for details. In all cases
the Positive connection is made via a Red connector and the Negative
connection is made via the Black connector.
Starter Motor
Glowplugs
Alternator
Ignition
Supply
Shutdown
Three Sets of Change Over Relay Contacts One set available via the
N/O, N/C and COM connectors Further two sets available terminals
inside the box fused via FU0208 at 2A
June 2009
143
TEXCEL SOFTWARE
11.1.1 Addressing
Each DX100 module has to have a unique address. This allows identification of an individual
module on a CAN network containing several modules. The address is set using the SW1
hexadecimal rotary switch on the Controller module. The table below shows the relationship
between the DX100 module address and its corresponding SW1 position setting.
DX100 Address
SW1 Position
DX100 Address
SW1 Position
DIO:01
DIO:05
DIO:02
DIO:06
DIO:03
DIO:07
DIO:04
DIO:08
144
1.
2.
Undo the retaining screws and remove the Controller module from the Terminator
module.
3.
Set the correct SW1 position on the replacement DX100 Controller module.
4.
Replace the new Controller module and tighten the retaining screws.
5.
6.
Reboot the RTP system to force the configuration file (.mce) to automatically be
downloaded to the DX100 module.
7.
IM 1347/1 ISSUE 5
2.
Reboot the RTP system to force the configuration file ( .mce ) to be automatically
downloaded to the DX100 module.
3.
CAN Channel
Status - Energised
Status - De-energised
MDC Comms Ok
MDC communicating
DX100 01 comms Ok
DX100 01 communicating
DX100 03 comms Ok
DX100 03 communicating
Comms to IO Ok
If any Device fails to communicate across the CAN Network checks the following:
June 2009
145
TEXCEL SOFTWARE
Channel Address
DIO:XX:AI:72
DIO:XX:AI:73
DIO:XX:AI:74
DIO:XX:AI:75
DIO:XX:AI:76
DIO:XX:AI:77
DIO:XX:AI:78
DIO:XX:AI:79
DIO:XX:AI:80
DIO:XX:AI:81
DIO:XX:AI:82
DIO:XX:AI:83
DIO:XX:AI:84
DIO:XX:AI:85
DIO:XX:AI:86
DIO:XX:AI:87
Node ID Number
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
Baud Rate
1 Mbits / S
1 Mbits / S
1 Mbits / S
1 Mbits / S
1 Mbits / S
1 Mbits / S
1 Mbits / S
1 Mbits / S
1 Mbits / S
1 Mbits / S
1 Mbits / S
1 Mbits / S
1 Mbits / S
1 Mbits / S
1 Mbits / S
1 Mbits / S
If an existing pressure transducer needs replacing then it must be replaced with a transducer
having the same configuration (Node ID number and Baud Rate).
If an additional pressure transducer is being added to the system, then the Node ID number for
the specific Channel Address and the Baud Rate must be supplied.
146