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DS830A
Stand-Alone Throttle Controller
USER MANUAL
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www.dynesystems.com
DPD-004-04
From Dyne Systems, Inc.
The DS830A Standalone Throttle Controller (SATC) is a standalone actuator/throttle position
controller. It is designed to control the position of any current Dyne Systems, Inc. (DS) actuator as
well as the older high-speed and high-torque actuators. No other actuators are officially supported,
although some may work. The user-friendly SATC is designed to operate in one of two configurations:
standalone or with an external control system. These two configurations are described in Section 2 of
this manual.
Feature Summary:
• The LCD display shows position command, actual position, SATC status, and fault information.
• Sub-D connections are used to interface with external equipment.
• Two modes of operation: Standalone Mode and External Control Mode.
• Two position command input types: 0 to +10 VDC or 0 to +20 mA.
• Position Feedback is available as a 0 to +10 VDC output.
• Control inputs and status/fault outputs offered at PLC-level (ie: 24 VDC).
• Fault detection (e.g. actuator stall, power fail, etc.).
• Field configurable (between Standalone and External Control Modes).
This manual is intended for use by qualified personnel only. All DS approved drawings (if included)
and specific instructions for this equipment must take precedence over general information contained
in this manual.
Thank you for purchasing this product from DS. Our staff is at your disposal. Should you need
information or support that is not found in this manual, please call (800) 657-0726.
CONTROLS, DYNAMOMETERS, SYSTEM INTEGRATION AND TEST CELL AUTOMATION
Dyne Systems, Inc. • W209 N17391 Industrial Drive • Jackson, Wisconsin 53037
Toll Free: 800.657.0726 • www.dynesystems.com
Dyne Systems • DS830A STANDALONE THROTTLE CONTROLLER
DPD-004-04 • © Copyright 2010 Dyne Systems, Inc.
Introduction
1
2
Dyne Systems • DS830A STANDALONE THROTTLE CONTROLLER
DPD-004-04 • © Copyright 2010 Dyne Systems, Inc.
TABLE OF CONTENTS
SECTION 1:
GENERAL INFORMATION
4
SAFETY...................................................................................................................................4
RECEIVING INSPECTION......................................................................................................4
DAMAGE CLAIMS...................................................................................................................4
IDENTIFY YOUR SATC............................................................................................................5
TRAINING................................................................................................................................5
SECTION 2:
CONFIGURATIONS
6
SECTION 3:
INSTALLATION ENVIRONMENT
7
SECTION 4:
INSTALLATION
8
MOUNTING.............................................................................................................................8
ELECTRICAL CONNECTIONS...............................................................................................8
SECTION 5:
CONNECTIONS
9
SUB-D CONNECTORS...........................................................................................................9
MS CONNECTORS............................................................................................................... 12
SECTION 6:
SECTION 7:
JUMPERS
13
OPERATION
14
FRONT PANEL DISPLAY....................................................................................................... 14
DIGITAL AND ANALOG I/O.................................................................................................... 15
SECTION 8:
CALIBRATION
17
CALIBRATION USING THE REMOTE STATION................................................................... 17
SETTING LOWER AND UPPER LIMIT.................................................................................. 18
CALIBRATION USING AN EXTERNAL CONTROL SYSTEM................................................20
SECTION 9:
ACTUATOR SUMMARY
21
SECTION 10:
PRODUCT WARRANTY
22
APPENDIX A:
DEFINITIONS / FORMULAS
23
APPENDIX B:
ACRONYMS
24
Dyne Systems • DS830A STANDALONE THROTTLE CONTROLLER
DPD-004-04 • © Copyright 2010 Dyne Systems, Inc.
Table of Contents
3
SECTION 1:
GENERAL INFORMATION
Dyne Systems, Inc. (hereafter referred to as DS) is the sole Original Equipment Manufacturer
(OEM) of the DS830A Standalone Throttle Controller (SATC). This manual, intended for
qualified personnel only, contains instructions for proper handling, installation, operation, and
maintenance of the SATC. All DS approved drawings (if included) and specific instructions
for this equipment must take precedence over general information contained in this manual.
All inquires related to the SATC should be directed to DS at (800) 657-0726.
SAFETY
Read your User Manual! Electrical equipment can be dangerous with the potential to
cause injury or death if operated and/or installed incorrectly. Become familiar with all safety
instructions and procedures. WARNING, CAUTION, WARRANTY and NOTE labels are
used throughout the manual to remind you of the hazards that exist. Know your equipment
before handling or working on it.
used to warn of the possibility of injury to personnel and damage to equipment
used to caution of potential hazards and unsafe practices
W
Warranty
Note:
used to alert to items that affect Warranty
used for special instructions related to safety, proper operation or maintenance
RECEIVING INSPECTION
Upon arrival of your equipment, check all items received against the packing slip to ensure
the shipment is complete. Then inspect for damage. Any evidence of rough handling may
be an indication of hidden damage.
The following checks are offered to aid your inspection:
1.
Inspect packaging and skid(s) for any mistreatment. Document and photograph any
signs of damage.
2.
Inspect housing to ensure there is no damage and that the unit is intact.
DAMAGE CLAIMS
In the event of damage, report it without delay to the Carrier and DS. DS’s warranty policy
does not cover shipping damage or lost material. It is important to file a damage claim with
the Carrier promptly. If you require assistance in settling the claim, contact DS. Refer to
equipment by Purchase Order, Model, and Serial Number, as shown on the nameplate of
the unit involved.
4
Dyne Systems • DS830A STANDALONE THROTTLE CONTROLLER
DPD-004-04 • © Copyright 2010 Dyne Systems, Inc.
1 - General Info
IDENTIFY YOUR SATC
The DS830A Standalone Throttle Controller (SATC) was configured at DS for your specific
application. Review the diagrams and verify you have the correct configuration:
•
Standalone
•
External Control
Locate the model and serial numbers on the SATC, and verify that they are the same as that
shown on the cover of this manual. This information should be used when contacting DS
customer support.
TRAINING
Training programs are an essential part of safe and correct operation. Training provides the
know-how necessary to obtain top performance from your equipment. DS recongnizes the
fact and will conduct training classes on-site or at the factory to educate personnel in safe
operating and maintenance procedures.
Dyne Systems • DS830A STANDALONE THROTTLE CONTROLLER
DPD-004-04 • © Copyright 2010 Dyne Systems, Inc.
1 - General Info
5
SECTION 2:
CONFIGURATIONS
Two modes of operation are supported: (1) Standalone and (2) External Control.
Standalone Mode
In the Standalone Mode of operation, On/Off and Reset buttons are provided on the front
panel. An analog potentiometer is also provided on the front panel to supply the user with
actuator position control. In this mode, the SATC must be located such that the LCD display
can be easily viewed by the operator. The display is the operator’s only feedback regarding
the user-defined actuator position command as well as the actual actuator position. The
LCD is also the operator’s only source of fault/status feedback.
The SATC, when functioning as a standalone controller, requires the use of a remote
station. This remote station is the user interface when calibrating the actuator and may be
helpful when the display is out of view. DS offers this remote station as part of the actuator
package.
Note: When using the SATC in a stand-alone configuration, the Soft Shutdown (SSD) input
(Pin 15) within the “THROTTLE CONTROL” connector must be jumped to 24VDC (Pin 6).
This ignores the SSD request normally given by the external control system.
External Control Mode
In the External Control Mode, all front panel pushbuttons and potentiometers are provided,
but are not required to function. The external control system provides the On/Off and
Reset input commands. Similarly, the analog position command, 0 to +10VDC or 0 to
20mA, is provided by an external supply, acting as an input position command. Although
not imperative, it is still helpful to locate the SATC such that the LCD is visible. Status and
position information is provided to the external control system for display elsewhere, but it is
also still displayed by the LCD.
Note: Detailed fault information is only available on the SATC’s LCD display, fault
information is not provided to the external control system.
Note: When using an external control system, the front panel buttons continue to function
but are not needed. The jumper between Pins 5 and 6 must be removed within the “AUX”
connector. The removal of this jumper renders the potentiometer inoperable, allowing for
external control through the “THROTTLE CONTROL” connector without conflict.
When used in conjunction with an external control system, calibration can be done without
the use of the DS remote station. However, the remote station can still be used, and can
prove to be beneficial. With a remote station, calibration can be performed away from the
SATC display. The remote station is offered as an option when an external control system is
being used.
Note: When using an external control system without a DSI remote station, the Soft
Shutdown (SSD) input (Pin 8) within the “REMOTE BASIC” connector must be jumped to
24VDC (Pin 1). This ignores the SSD request normally given by the DSI remote station.
6
Dyne Systems • DS830A STANDALONE THROTTLE CONTROLLER
DPD-004-04 • © Copyright 2010 Dyne Systems, Inc.
2 - Configurations
SECTION 3:
INSTALLATION ENVIRONMENT
The SATC should be mounted so it is not exposed to severe shock and/or vibrations. If
adverse conditions are anticipated, the SATC can be mounted using vibration-damping
materials.
The atmosphere should be free of corrosive gases.
The atmosphere should be free of vapors or powders that could cause fire or explosion.
Relative humidity should be 0% to 95%, non-condensing.
Temperature range should be 32 °F – 90 °F (0 °C – 32.2 °C).
Dyne Systems • DS830A STANDALONE THROTTLE CONTROLLER
DPD-004-04 • © Copyright 2010 Dyne Systems, Inc.
3 - Environment
7
SECTION 4:
INSTALLATION
MOUNTING
The SATC comes in a 3.5”h x 17”w x 15”d enclosure that is designed to fit into a standard
19” rack mount enclosure. DS provides rack mount brackets for proper installation. Unless
previously specified, the end user is responsible for providing the mounting system.
Note: The SATC requires air to circulate through its enclosure for proper cooling. Be sure to
provide some space at the front and rear of the enclosure to allow air flow.
ELECTRICAL CONNECTIONS
Connections may vary with different configurations; all electrical connections should
correspond with the schematic provided by DS at time of delivery. General connection
information is provided to show the location of all possible connections to the SATC, for pinouts of all connections, refer to Section 5 - Connections.
Note: Only a qualified electrician should install the SATC. All installations should comply
with the most current version of the National Electric Code (NEC) as well as all local codes
and regulations.
Refer to Figure 4.1 for SATC rear panel connector locations.
Figure 4.1 - SATC Rear Panel Connector Locations
8
Dyne Systems • DS830A STANDALONE THROTTLE CONTROLLER
DPD-004-04 • © Copyright 2010 Dyne Systems, Inc.
4 - Installation
SECTION 5:
CONNECTIONS
The SATC has four Sub-D Connectors and two 6-Pin MS Connectors that interface with
external devices.
All of the digital Inputs and Outputs (I/O) use PLC-level (i.e. +24 VDC) logic. +24 VDC is
provided in many connectors; thus, the external control system only needs to process the
+24 VDC, and supply it back into the desired inputs via dry contact relays.
SUB-D CONNECTORS
ACTUATOR ENCODER (15-Pin Female Sub-D): Actuator Position Feedback
Pin #
Function
Comments
1
Common
Encoder Common
2
5VDC (o)
Encoder Power
3
A (i)
Encoder Signal A
4
A’ (i)
Encoder Signal A Not
5
B (i)
Encoder Signal B
6
B’ (i)
Encoder Signal B Not
7
ILK (i)
Encoder Operation Feedback
8
NC
Not Connected
9
Common
Encoder Common
10
5VDC (o)
Encoder Power
11
A (i)
Encoder Signal A
12
A’ (i)
Encoder Signal A Not
13
B (i)
Encoder Signal B
14
B’ (i)
Encoder Signal B Not
15
ILK (i)
Encoder Operation Feedback
Table 5.1
REMOTE BASIC (15-Pin Male Sub-D): Remote Station Control
Pin #
Function
Comments
1
24VDC (o)
Remote Station Power
2
Common
Remote Station Common
3
Button_Up (i)
Remote Station Up Button
4
LED_Lower (o)
Remote Station Lower Limit LED Indicator
5
LED_Upper (o)
Remote Station Upper Limit LED Indicator
6
Button_Down (i)
Remote Station Down Button
7
LED_Accept (o)
Remote Station Accept Limit LED Indicator
8
Button_Soft_Shutdown (i)
Remote Station Soft Shutdown Button
9
24VDC (o)
Remote Station Power
10
Common
Remote Station Common
11
NC
Not Connected
12
NC
Not Connected
13
NC
Not Connected
14
Button_Enter (i)
Remote Station Enter Button
15
LED_Fault (o)
Remote Station Fault LED Indicator
Table 5.2
Dyne Systems • DS830A STANDALONE THROTTLE CONTROLLER
DPD-004-04 • © Copyright 2010 Dyne Systems, Inc.
5 - Connections
9
SUB-D CONNECTORS (CONTINUED)
AUX (25-Pin Female Sub-D): External Position Command Input/Position Feedback
Pin #
Function
Comments
1
NC
Not Connected
2
NC
Not Connected
3
NC
Not Connected
4
NC
Not Connected
5
NC
Not Connected
6
NC
Not Connected
7
NC
Not Connected
8
NC
Not Connected
9
NC
Not Connected
10
Position Input Signal (i)
Position Command Input Signal, Jumped to Pin #12 for
use with the Front Panel Potentiometer
11
Position Feedback Signal (o)
Actual Position Feedback
12
Position (POT) Wiper
Position Voltage from Front Panel Potentiometer
(Jumped to Pin #10 when used)
13
NC
Not Connected
14
NC
Not Connected
15
NC
Not Connected
16
NC
Not Connected
17
NC
Not Connected
18
NC
Not Connected
19
NC
Not Connected
20
NC
Not Connected
21
NC
Not Connected
22
NC
Not Connected
23
Position Input Common
Position Command Input Signal Common
24
Position Feedback Common
Actual Position Feedback Common
25
NC
Not Connected
Table 5.3
10
Dyne Systems • DS830A STANDALONE THROTTLE CONTROLLER
DPD-004-04 • © Copyright 2010 Dyne Systems, Inc.
5 - Connections
THROTTLE CONTROL (37-Pin Female Sub-D): Customer Supplied External Control Interface
Pin #
Function
Comments
1
Position Command (i)
Position Command Input Voltage from External
Control System
2
Ai Common
Analog Common (+/- 15VDC)
3
Actuator On (i)
Actuator On/Off Control Input from External Control
System
4
(Pi) Power Common
Power Common (+24VDC)
5
(Pi) Power Common
Power Common (+24VDC)
6
Power (+24VDC) (o)
Output Power (+24VDC) to system safeties/
controls.
7
NC
Not Connected
8
Actuator Position Feedback (o)
Actual Actuator Position Feedback Signal
9
Ai Common
Analog Common (+/- 15VDC)
10
NC
Not Connected
11
(Pi) Power Common
Power Common (+24VDC)
12
Remote Up Push Button (i)
Remote Push Button for Up Command (Used for
calibration)
13
Remote Down Push Button (i)
Remote Push Button for Down Command (Used for
calibration)
14
Remote Enter Push Button (i)
Remote Push Button for Enter Command (Used for
calibration)
15
Remote Soft Shutdown Push Button (i)
Remote Push Button for Soft Shutdown (Used for
calibration; also functions while system is in use)
16
NC
Not Connected
17
NC
Not Connected
18
NC
Not Connected
19
NC
Not Connected
20
Ai Common
Analog Common (+/- 15VDC)
21
Reset Command (i)
Reset Command from External Control System
22
NC
Not Connected
23
SATC On Feedback (o)
SATC On Feedback to External Control System
24
SATC OK Feedback (o)
SATC OK Feedback to External Control System
25
Power (+24VDC) (o)
Output Power (+24VDC) to system safeties/
controls.
26
NC
Not Connected
27
Ai Common
Analog Common (+/- 15VDC)
28
NC
Not Connected
29
(Pi) Power Common
Power Common (+24VDC)
30
Remote Upper LED (o)
Remote LED to indicate the Upper Limit Set during
Calibration
31
Remote Lower LED (o)
Remote LED to indicate Lower Limit Set during
Calibration
32
Remote Accept LED (o)
Remote LED to indicate the Acceptance of the
newly entered limits
33
Remote Fault LED (o)
Remote LED to indicate that the system has faulted
34
NC
Not Connected
35
NC
Not Connected
36
NC
Not Connected
37
NC
Not Connected
Table 5.4
Dyne Systems • DS830A STANDALONE THROTTLE CONTROLLER
DPD-004-04 • © Copyright 2010 Dyne Systems, Inc.
5 - Connections
11
MS CONNECTORS
ACTUATOR POWER (6-Pin Male MS Connector): Input Power (120VAC)
Pin #
Function
Comments
A
Hot 120VAC Input (i)
Hot 120VAC Input Power
B
Neutral 120VAC (i)
Neutral 120VAC Input Power
C
GND
Ground
D
NC
Not Connected
E
NC
Not Connected
F
NC
Not Connected
Table 5.5
ACTUATOR MOTOR (6-Pin Female MS Connector): Output Actuator Power
Pin #
Function
Comments
A
(+) Actuator Armature (o)
Positive Actuator Output Power
B
NC
Not Connected
C
NC
Not Connected
D
(-) Actuator Armature (o)
Negative Actuator Output Power
E
(-) Actuator Armature (o)
Negative Actuator Output Power
F
(+) Actuator Armature (o)
Positive Actuator Output Power
Table 5.6
12
Dyne Systems • DS830A STANDALONE THROTTLE CONTROLLER
DPD-004-04 • © Copyright 2010 Dyne Systems, Inc.
5 - Connections
SECTION 6:
JUMPERS
Jumpers are installed at DS before shipment per the customer’s specified configuration.
However, Table 6.1 may be needed for future additions to a system, or for troubleshooting a
system.
Jumper
Function
JP1
Position command type
IN = 0 to +20 mA current
OUT = 0 to +10 VDC voltage
OUT = DEFAULT
JP2
Install to connect the (-) terminal of the differential input amplifier to COMMON
IN = Single-Ended input operation
OUT = Differential input operation
IN = DEFAULT
JP3
IN = Override Soft Shut Down input from external controller
OUT = Accept Soft Shut Down input from external controller
OUT = DEFAULT
JP4
IN = Override Soft Shut Down input from possible front panel input
OUT = Accept Soft Shut Down input from possible front panel input
IN = DEFAULT (As no front panel Soft Shut Down is offered on this model)
JP5
IN = Override Soft Shut Down input from Remote Station box
OUT: Accept Soft Shut Down input from Remote Station Box
OUT = DEFAULT
JP6 – JP9
Solid wire. Cannot be removed.
Table 6.1 - Jumpers
Dyne Systems • DS830A STANDALONE THROTTLE CONTROLLER
DPD-004-04 • © Copyright 2010 Dyne Systems, Inc.
6 - Jumpers
13
SECTION 7:
OPERATION
FRONT PANEL DISPLAY
The front panel display layout is shown below:
SATC Status
SATC: OK
Off
Input Command
----- %
-----%
SATC State
Actuator Position
Figure 7.1 - Example of Main Screen
The upper-left value displays the operational status of the system. When operating properly,
the SATC will always read “OK” or “Reset”. When the SATC is in a fault condition, an entirely
different screen is displayed describing the fault.
The upper-right value displays the current operating state. The SATC state will always read
“Off”, “ON”, SSD (Soft Shutdown) or “RTZ” (Return To Zero). The SSD and RTZ states can
only be cleared by a reset; however, the reset is ignored until the SSD/RTZ has completed or
5 seconds has expired (whichever occurs first).
The lower-left value displays the commanded (input) position as a percentage of the total
input range.
The lower-right value displays the actual actuator position as a percentage of the total
actuator range.
Note: When the SATC is in a fault condition, an entirely different screen from the one above
is displayed describing the fault. An example of a fault screen is shown below.
SATC:
1 Error
No Encoder ILK
Figure 7.2 - Example of Fault Screen
14
Dyne Systems • DS830A STANDALONE THROTTLE CONTROLLER
DPD-004-04 • © Copyright 2010 Dyne Systems, Inc.
7 - Operation
DIGITAL AND ANALOG I/O
Note: As stated in a previous section, all digital I/O is +24VDC (PLC Level) logic.
Inputs
The SATC is entirely controlled via digital and analog inputs. In a standalone configuration,
these inputs are directly wired to the front panel’s pushbuttons and potentiometer. When
used in conjunction with an external control system, the control system commands all inputs,
hence the front panel controls are no longer required to function.
All connections that can be used with an external system are described in the Section 5 Connections. The “Actuator ON” input is used to enable/disable the SATC. The “Reset” input
is used to clear fault conditions.
Note: The “SOFT SHUTDOWN” button on the Remote Station is also a valid active input.
When pressed, the SATC will enable itself (if not already enabled), will return the actuator to
the zero position, and finally will disable itself. The resulting SSD condition is NOT a fault;
however, it does prevent the SATC from being re-enabled and must be cleared out via a
“Reset” command.
Note: To minimize/eliminate the effects of offset voltages at the analog position command
input, the SATC ignores all command voltages less than 20 mV (i.e. 0.2% position).
Outputs
When using an external control system, several digital outputs are available that annunciate
the state of the SATC. All digital outputs are made available through the “THROTTLE
CONTROL” connector as described in Section 5 - Connections. These outputs can either
be used by the external control system, or they can be wired directly to 24VDC lamps to
indicate the status of the SATC.
Note: Each 24VDC output can source up to 1A, with a limit of 1A available for all outputs
combined.
A 0 to +10 VDC analog position feedback output is also available at the “AUX” connector,
as described in Section 5 - Connections. This output indicates the throttle position to an
external control system or other customer defined indicator. This output is reasonably
accurate; however, if used by an external control system, the external control system should
zero and span the position feedback as needed to attain the desired accuracy.
Dyne Systems • DS830A STANDALONE THROTTLE CONTROLLER
DPD-004-04 • © Copyright 2010 Dyne Systems, Inc.
7 - Operation
15
DIGITAL AND ANALOG I/O (CONTINUED)
Faults
When a fault occurs, the SATC performs one of two actions (depending on the type of fault).
Some faults cause the actuator to return to the zero position (i.e. RTZ) and then disable the
SATC. Other faults simply disable the SATC and leave the actuator position as is (usually to
prevent damage to the SATC). After resolving the fault condition, the SATC can be cleared
by issuing a reset command.
Note: Detailed fault descriptions are available via the LCD display only.
The actuator may remain at previous position even after clearing and resetting
some faults. Use caution when restarting the system as the throttle may still be set
at the previous position.
Fault
Action
Cause
RTZ Input
RTZ
+24 VDC is no longer present at the RTZ input. This fault input condition is usually
caused by the external control system.
No Encoder ILK
Disable
The actuator cable is disconnected or there is an issue with the connection. There may
be issues with the internal encoder assembly.
Invalid Span
Disable
The actuator is improperly calibrated. This fault occurs only when the operator attempts
to enable the SATC. Successfully re-calibrate the upper and lower limits to eliminate this
fault.
Over-Temperature
Disable
The H-Bridge is too hot. Wait for the SATC to cool. Most likely caused by rapid actuator
movement for a long period of time.
Over-Current
Disable
Usually occurs along with the “Actuator Stalled” fault (listed below) since excessive
currents are mainly caused by stalled actuators.
Power Fail
RTZ
The head supply voltage has fallen below +20 VDC.
This fault always occurs when the SATC is powered down.
Actuator Stalled
Disable
Actuator movement is blocked. Could also occur due to improper calibration of upper and
lower limits.
Table 7.1 - Faults, Actions and Causes
16
Dyne Systems • DS830A STANDALONE THROTTLE CONTROLLER
DPD-004-04 • © Copyright 2010 Dyne Systems, Inc.
7 - Operation
SECTION 8:
CALIBRATION
Actuator calibration is a critical part of the overall operation of the SATC. It is vital that the
Upper and Lower Limits of the actuator movement be correctly set and periodically adjusted
to compensate for drift. Calibration can be initiated, performed, and saved using the two
following methods; (1) using the pushbuttons on the Remote Station (2) using the I/O
provided through the “THROTTLE CONTROL” connector.
Note: It is assumed that the LCD display is visible during calibration when using the
Remote Station; however, this is not a requirement. Familiarity with the calibration
procedure, combined with feedback to the operator (via the LED’s on the Remote Station)
ultimately allows calibration to be performed with only the Remote Station in hand (and the
LCD display not necessarily visible).
CALIBRATION USING THE REMOTE STATION
Initiating Calibration
To begin calibration, supply main power to the SATC but do not enable the actuator. Press
and hold the “ENTER” button (on the Remote Station) for 2 seconds, the SATC will then
enter calibration mode. When in this mode, the LCD will display “SET LOWER” as the first
calibration menu item and all four LED’s on the Remote Station will flash several times. To
ensure proper operation of the actuator the following menu items must be addressed during
calibration “Lower Limit,” “Upper Limit,” and direction of rotation. These limits must also be
tested and saved before exiting the set up menu.
Note: To navigate through the calibration menu, press the “UP” and “DOWN” buttons to
cycle through the menu items. Press the “ENTER” button to select the desired task.
Note: The “Lower” and “Upper” limits are defined as the maximum allowable distance of
travel by the actuator arm in a given direction (Up or Down).
Table 8.1 lists the headings within the calibration menu along with the LED indication at that
point within the menu.
Calibration Task
LED status
Description
SET LOWER
LOWER LIMIT = ON
Set the lower limit (i.e. 0% position)
SET UPPER
UPPER LIMIT = ON
Set the upper limit (i.e. 100% position)
TEST LIMITS
All are OFF.
Test limits by jogging the actuator.
EXIT & SAVE
ACCEPT LIMIT = blinks
FAULT = blinks
EXIT & CANCEL
FAULT = blinks
DIRECTION
All are OFF.
Define direction of actuator movement, viewed from shaft end,
when moving from 0% to 100% position. Selections are:
Clockwise-CW
Counter Clockwise-CCW
Note: If the actuator moves opposite to the configured direction,
there is a wiring error in the SATC. Contact DS.
MOVEMENT TYPE
All are OFF.
Selects the type of actuator movement during calibration.
Manual - move actuator by hand
Powered - use UP and DOWN buttons
Table 8.1
Dyne Systems • DS830A STANDALONE THROTTLE CONTROLLER
DPD-004-04 • © Copyright 2010 Dyne Systems, Inc.
8 - Calibration
17
Choosing Direction of Rotation
To select the direction for the actuator, navigate to the “DIRECTION” menu item, press
the “ENTER” button and select the desired direction. Press “ENTER” again to accept the
direction.
Choosing Calibration Movement Type
To select the type of Calibration (Powered or Manual), navigate to the “MOVEMENT TYPE”
menu item, press the “ENTER” button and select the desired type of calibration. Press
“ENTER” again to accept the type.
Note:
Powered and Manual calibration types are discussed in the next sub-section.
SETTING LOWER AND UPPER LIMIT
Powered Calibration
When setting the upper and lower limits using “Powered” calibration, follow the below
procedure.
1.
Navigate to the appropriate menu item (SET LOWER or SET UPPER) and press the
“ENTER” button to begin the setup.
2.
Press the “UP” and “DOWN” buttons to cause small movements in the actuator position.
Holding these buttons down causes the actuator to move rapidly (i.e. slew) in the
respective direction.
3.
When the new Upper (or Lower) limit is established, press the “ENTER” button. On the
remote station, both the “ACCEPT” and respective “LOWER” or “UPPER” LED will turn
on. This indicates a successful setting of the limit.
4.
Press “ENTER” again to accept the limit.
5.
Repeat this process to complete the calibration of both the upper and lower limits.
Manual Calibration
When setting the upper and lower limits using “Manual” calibration, follow the below
procedure.
18
1.
Navigate to the appropriate menu item (SET LOWER or SET UPPER) and press the
“ENTER” button to begin the setup.
2.
Move the actuator, free hand, to the desired position. The “UP” and “DOWN” buttons on
the Remote Station are no longer functional.
3.
When the new Upper (or Lower) limit is established, press the “ENTER” button. On the
remote station, both the “ACCEPT” and respective “LOWER” or “UPPER” LED will turn
on. This indicates a successful setting of the limit.
4.
Press “ENTER” again to accept the limit.
5.
Repeat this process to complete the calibration of both the upper and lower limits.
Dyne Systems • DS830A STANDALONE THROTTLE CONTROLLER
DPD-004-04 • © Copyright 2010 Dyne Systems, Inc.
8 - Calibration
LCD display during calibration
If visible, the LCD display offers valuable feedback during calibration. When setting the upper
or lower limit, the position of the actuator is shown as a count. When a desired set-point is
reached and selected, the following acceptance screen is displayed.
ACCEPT UPPER ?
X Yes
No
Retry
Figure 8.1 - Calibration Display
The default selection is set to “Yes”. Press the “UP” and “DOWN” buttons to change the
selection to “No” or “Retry” as needed. Press the “ENTER” button to make the desired
selection (usually “Yes”).
As shown in the ACTUATOR SUMMARY section (Section 9), each DS actuator has an
encoder count range. The new lower and upper limits being set must be within the range
specified for the actuator. If the encoder count range of the selected actuator is not reached
or exceeded, the LCD will display an appropriate error message (shown below).
-> INVALID SPAN
Min Span = 10,000
-> INVALID SPAN
Max Span = 42000
Figure 8.2 - Actuator Summary Displays
To fix an invalid limit, use the “DOWN” button to navigate back to the desired menu item and
go through setting that limit again.
Testing of the lower and upper limits is not available until limits have been set within the
specified encoder count range.
Note: If the standard DS actuator stop-plate is installed (highly recommended), it is
impossible to create excessively large span values. Insufficient span is the most frequently
occurring error.
Dyne Systems • DS830A STANDALONE THROTTLE CONTROLLER
DPD-004-04 • © Copyright 2010 Dyne Systems, Inc.
8 - Calibration
19
Testing the lower and upper limits
After navigating to the “TEST LIMITS” menu item, hit “ENTER.” Once in the menu, press
and hold the “ENTER” button to rotate the actuator towards the Upper limit (i.e. the 100%
position). Release the “ENTER” button to allow the actuator to rotate back towards the
Lower limit (i.e. the 0% position). After successfully spanning the limits, press the “SOFT
SHUTDOWN” button to return to the main calibration menu.
Saving new limits
To save the new Lower and Upper limits, navigate to the “EXIT & SAVE” menu item and
press “ENTER”.
Exiting without saving new limits
To exit the calibration menu without saving new limits, navigate to the “EXIT & CANCEL”
menu item and press “ENTER”.
CALIBRATION USING AN EXTERNAL CONTROL SYSTEM
The same procedure is followed when calibrating using an external control system.
However, the control that was provided by the Remote Station now must be provided by
the external control system. This control is interfaced with the SATC via the “THROTTLE
CONTROL” connector. Refer to Section 5 - Connections for information on the “THROTTLE
CONTROL” connector.
20
Dyne Systems • DS830A STANDALONE THROTTLE CONTROLLER
DPD-004-04 • © Copyright 2010 Dyne Systems, Inc.
8 - Calibration
SECTION 9:
ACTUATOR SUMMARY
Over the years, DS has used three different actuators. The latest actuator is the
“ACTUATOR-03” standard model. The SATC can be used with all three actuators. Be sure
that the actuator in use is listed below, otherwise calibration faults and other issues may
occur.
The Table 9.1 shows all three DS actuators and some of their specifications.
Actuator
Voltage
(Volts)
Encoder
(PPR)
Max Move
Rate
%/sec
Gear
Ratio
Nominal
Counts
Minimum
Counts
Maximum
Counts
Standard
24
200
200
246:1
38,000
10,000
42,000
Old HighTorque
12
200
400
246:1
38,000
10,000
42,000
Old HighSpeed
12
500
700
134:1
52,000
10,000
57,000
Table 9.1
Note: SATC units purchased before September 2010 will have higher minimum count
requirements for the listed actuators. These requirements are as follows:
• Standard Actuator:
27,000 Counts
• Old High-Torque Actuator:
27,000 Counts
• Old High-Speed Actuator:
36,000 Counts
Note: The SATC board will never command movement rates beyond 500%/sec even
though the older high-speed actuators are capable of higher rates.
Note: If the actuator in use is not listed above please contact DS.
Dyne Systems • DS830A STANDALONE THROTTLE CONTROLLER
DPD-004-04 • © Copyright 2010 Dyne Systems, Inc.
9 - Actuator
21
SECTION 10: PRODUCT WARRANTY
WARRANTY, REMEDIES AND LIMITATIONS: DyneSystems warrants the following equipment will conform to published specifications
and be free from faulty material or workmanship for the listed time period from date of shipment or onsite repair:
New Controls12 Months
Repaired Controls
3 Months
Service Calls
3 Months
This warranty covers properly installed equipment used within specified limits and ambient conditions and is limited to repair or
replacement of equipment proving defective at DyneSystems. For warranty to be valid, Buyer must conform to DyneSystems’ factory
specifications. If applicable, terms of Warranty Validation and Delivery Certification must be met for warranty to be valid. This warranty
does not apply to experimental, developmental or non-standards Goods and Products which are sold “as is”, “where is”. DyneSystems
shall not be liable for labor costs associated with removing, reinstalling or delivering any equipment. Transportation costs associated
with delivering products to DyneSystems under the warranty are the responsibility of the Customer. Transportation costs associated
with returning products to the Customer under the warranty are the responsibility of DyneSystems. If warranty service is deemed
necessary and product (i.e. controls, small dynamometer, etc) can be shipped to DyneSystems then it is expected that product be sent
to DyneSystems; however, if Customer wants warranty work to be performed onsite and DyneSystems deems it feasible then Customer
will be responsible for travel hours and travel / transportation costs. DyneSystems is not liable for costs incurred such as loss of work
time or production time or for loss of profits or other damages, including, but not limited to consequential damage.
THE FOREGOING WARRANTIES ARE EXCLUSIVE AND ARE GIVEN AND ACCEPTED IN LIEU OF ANY AND ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION, THE IMPLIED WARRANTIES OF MERCHANTABILITY
AND FITNESS FOR A PARTICULAR PURPOSE. THE REMEDIES OF BUYER FOR ANY BREACH OF WARRANTY SHALL BE
LIMITED TO THOSE PROVIDED HEREIN, AND FOR DELAY OR NON-DELIVERY WHICH IS NOT EXCUSABLE, TO THE PURCHASE
PRICE OF THE GOODS IN RESPECT OF WHICH THE DELAY OR NON-DELIVERY IS CLAIMED, TO THE EXCLUSION OF ANY
AND ALL OTHER REMEDIES. IN NO EVENT SHALL DYNE SYSTEMS BE LIABLE FOR SPECIAL, INDIRECT OR CONSEQUENTIAL
DAMAGES, INCLUDING WITHOUT LIMITATION, LOSS OF USE OR PROFITS. NO AGREEMENT VARYING OR EXTENDING THE
FOREGOING WARRANTIES, REMEDIES OR THIS LIMITATION WILL BE BINDING UPON DYNE SYSTEMS UNLESS IN WRITING
SIGNED BY A DULY AUTHORIZED OFFICER OF DYNE SYSTEMS. DYNE SYSTEMS’ LIABILITY FOR FAILURE TO COMPLY WITH
ANY WARRANTY OR REPRESENTATION HEREUNDER SHALL BE LIMITED TO THE VALUE OF THE GOODS SOLD HEREUNDER.
Excluding equipment made for integrated systems supplied or made by DyneSystems, DyneSystems makes no warranty on the use of
the equipment in combination with other products or in the practice of any process and if a claim, suit or action is based thereon, Buyer
shall defend, indemnify and save DyneSystems harmless therefrom.
LIMITATION OF LIABILITY: DyneSystems’ liability for defective or nonconforming products, whether based on breach of warranty
negligent manufacture or product liability, is exclusively limited to repair or replacement, at DyneSystems’ election, of such products.
DyneSystems assumes no risk and shall be subject to no liability for any damages or loss resulting from the specific use or application
made of the Products. DyneSystems’ liability for any other claim, whether based on breach of contract, negligence or product liability,
relating to the products shall not exceed the price paid by Buyer for such Products. In no event will DyneSystems be liable for any
special, incidental or consequential damages, including loss of use, loss of profit, claims of third parties, or damages arising from bodily
injury, or death, however caused, whether by the negligence of DyneSystems or otherwise.
EQUIPMENT MADE BY OTHERS: Any items supplied that are not manufactured by DyneSystems are covered by the original
manufacturer’s warranty and not by a DyneSystems warranty.
CUSTOMER SUPPLIED PRODUCT: DyneSystems accepts customer provided equipment as a courtesy only. DyneSystems is not
responsible for determining suitability of customer’s equipment for a particular purpose. Repair or configuration of customer-supplied
equipment will be charged at DyneSystems normal rate.
22
Dyne Systems • DS830A STANDALONE THROTTLE CONTROLLER
DPD-004-04 • © Copyright 2010 Dyne Systems, Inc.
10 - Warranty
APPENDIX A: DEFINITIONS / FORMULAS
Ohm’s Law
Ohm’s Law defines the relationships between (P) power, (E) voltage, (I) current, and (R)
resistance. One ohm is the resistance value through which one volt will maintain a current of
one ampere.
I (Current) = P (Power) / E (Voltage)
I (Current) = E (Voltage) / R (Resistance)
(I) Current is what flows on a wire or conductor like water flowing down a river. Current flows
from negative to positive on the surface of a conductor. Current is measured in (A) amperes
or amps.
(E) Voltage is the difference in electrical potential between two points in a circuit. It is the
push or pressure behind current flow through a circuit, and is measured in (V) volts.
(R) Resistance determines how much current will flow through a component. Resistors are
used to control voltage and current levels. A very high resistance allows a small amount of
current to flow. A very low resistance allows a large amount of current to flow. Resistance is
measured in ohms.
(P) Power is the amount of current times the voltage level at a given point measured in
wattage or watts.
Dyne Systems • DS830A STANDALONE THROTTLE CONTROLLER
DPD-004-04 • © Copyright 2010 Dyne Systems, Inc.
Appendix A
23
APPENDIX B: DRAWINGS AND SCHEMATICS
24
Dyne Systems • DS830A STANDALONE THROTTLE CONTROLLER
DPD-004-04 • © Copyright 2010 Dyne Systems, Inc.
Appendix A
APPENDIX C: ACRONYMS
°C - Degrees Centigrade
CW - Clockwise
CCW - Counter Clockwise
°F - Degrees Fahrenheit
GND - Ground
I/O - Input or Output
(i) - Input
(o) - Output
JP - Jumper
LCD - Liquid Crystal Display
LED - Light Emitting Diode
NC - Not Connected
NEC - National Electric Code
RTZ - Return To Zero
SATC - Standalone Throttle Controller
SSD - Soft Shutdown
VAC - Volts Alternating Current
VDC - Volts Direct Current
Dyne Systems • DS830A STANDALONE THROTTLE CONTROLLER
DPD-004-04 • © Copyright 2010 Dyne Systems, Inc.
Appendix B
25