Speed Setup: Difference between revisions

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(Created page with "Video available for this topic: https://www.youtube.com/watch?v=PAmjcq7CPt0 === ENGINE CONDITION === For proper AFRC operation, it is critical that the engine be in good operational status. Verify the following before running the AFRC: * Valves are adjusted to factory specification * Spark plugs are properly gapped and in good condition * Cylinders have good compression * Mixers are in good condition and regulator fuel pressure is set to factory specification * Fuel co...")
 
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Video available for this topic: https://www.youtube.com/watch?v=PAmjcq7CPt0
After initial install, or when settings changes are needed, the Governor setup screens are used. The setup screens are accessed by selecting “Setup” on the Governor Home screen, then the “Governor Setup” button. An access level of ''Setup'' or higher is needed to access these screens.


=== ENGINE CONDITION ===
=== STEP 1: ENGINE SETTINGS ===
For proper AFRC operation, it is critical that the engine be in good operational status. Verify the following before running the AFRC:
Step 1 of governor setup specifies the basic engine settings. These are the number of flywheel teeth, the idle speed for when the panel switch is in “Idle”, and the speed alarm values. After initial setup, these settings are not commonly changed.


* Valves are adjusted to factory specification
<nowiki>*</nowiki>Insert Image*
* Spark plugs are properly gapped and in good condition
* Cylinders have good compression
* Mixers are in good condition and regulator fuel pressure is set to factory specification
* Fuel connections are secure and leak-free
* Ignition system functioning correctly and timing set appropriately for fuel composition
 
=== CONTROLLER SETUP ===
While the engine is not running, perform the following steps to prepare the controller for operation:
 
* AFRC module is installed and wired
* Digital power valve(s) are installed
* Secure the front panel of the EIM to the enclosure by re-tightening the four (4) front panel screws
* Run signal source is properly connected
* Run signal source is properly selected on the Run Signal Trigger screen (Pg. 10)
* Fuel connections are secure and leak-free
* Load valve manual adjustments on external dynamic valves are fully open (full rich, or seven turns from fully closed) for startup only
* Enter Setup or Engineering mode on the controller by entering the appropriate password
* Set the “Control” toggle button on the AFRC Home screen (Lite Pg. 300, Adv. Pg. 200) to “Manual”
 
The engine can now be started.
 
=== VALVE SETUP ===
No valve setup required unless an External Dynamic or 600 Series valve is being used. For information on these valve types, their setup, and operation refer to “APPENDIX D. EXTERNAL DYNAMIC AND 600 SERIES VALVES”.
 
=== Sensor Setup ===
The AFRC Advanced has the following optional sensor inputs available for process monitoring, run signal, and mapping:
 
* Manifold Pressure Sensors (two available)
* "Manifold Press Left" and "Manifold Press Right"
* Single bank configurations utilize the "Manifold Press Left" input
* Sensors are pre-configured for the system and can only be enabled and disabled
* Analog (one available)
* "ANALOG"
* Configuration to 0-5V, 1-5V, or 4-20mA
* Oil Pressure Switch (one available)
* "Oil Pressure Switch"
* Pre-configured as normally open (N/O) and can only be enabled or disabled
* Thermistor (one available)
* "Ambient"
* Thermocouple (one available)
* "Manifold"
* Type-K thermocouple only
* Magnetic Pickup (one available)
* "RPM"
* 1-100 Volts
 
The AFRC Lite has the following optional sensor available for process monitoring and mapping:
 
* Manifold Pressure Sensor (one available)
* “Manifold Press”
* Sensor is pre-configured for the system and can only be enabled or disabled
 
The different sensor types are available for setup by selecting their respected buttons on the top of the screen.


=== Configuring the Analog and Discrete Inputs ===
''Setup Step 1''
To setup the manifold pressure sensors or the oil pressure switch, simply select the “Enable” toggle box next to the sensor label. Darker colored toggle buttons indicate the sensor is actively enabled.


For the general purpose “ANALOG” input, the following fields are required:
If an underspeed alarm is not needed, it can be set to “0”. The speed alarm will always shut down the engine regardless of the control mode or condition. If an RPM setpoint higher than the overspeed alarm is specified, the setting will be allowed, but once the engine hits the overspeed value it will be shut down.


* Name – Label of the sensor that will be displayed within the AFRC’s user interface
=== STEP 2: CONTROL SELECTION ===
* Enabled – Activates sensor input
In step 2 of the governor setup, the setpoint type and value are specified. For the fixed speed control type, the setpoint is an engine RPM. For suction or discharge control, the setpoint is a PSI value.
* Output – 4-20mA, 0-5 Volt, or 1-5V sensor output type
* Low Scale – Lowest output value of the sensor
* Full Scale – Highest output value of the sensor
* Units – Units of the sensor


<nowiki>*</nowiki>Insert Image*
<nowiki>*</nowiki>Insert Image*


AI/DI Sensor Setup Screen
If fixed speed control is selected, the setup will skip to Governor Setup Review after this step.


=== Configuring the Temperature Inputs ===
For pressure control modes, the control type can be "Setpoint, Deadband" or "Linear Ramp". (Note: Linear Ramp mode requires software version 848 or newer).
The thermocouple and thermistor inputs only require their respected “Enable” toggle buttons to be selected in order to be operational.


=== Configuring RPM ===
Setpoint, Deadband: In this mode, a pressure setpoint and deadband is given. If the pressure is outside of the range [Setpoint +/- Deadband], the speed will change (with the direction depending on if it is suction or discharge control). Within the deadband, the speed will not change. The speed will increase or decrease only until the speed hits a range limit, given on the next setup page.
The RPM input is configured by providing the pulses per revolution and selecting the “Enable” toggle button. This option is only available on the AFRC Advanced.


=== RUN SIGNAL ===
Linear Ramp: For linear ramp mode, a low and high pressure will be given. Between this high and low value, the speed target will be calculated linearly with respect to the low and high operating RPM. Example setup (suction control):
By default, the run signal selection is set to “Auto-Detect”, which scans enabled sensors for each module. The AFRC Advanced has three applicable inputs:


* Pre-catalyst thermocouple (terminals 24 and 25)
* Low pressure: 20 PSI
* Oil pressure switch (terminals 39 and 40)
* High pressure: 30 PSI
* RPM (terminals 17 and 18)
* Low RPM: 1200
* High RPM: 1600


If an AFRC Lite is installed, the only available run signal trigger sensor available is the pre-catalyst thermocouple (terminals 21 and 22).
In the above example, if the current suction input pressure is 25 PSI, the RPM target will be 1400 RPM.


Additionally, the run signal can be generated from a connected EMD, if equipped, using the following inputs:
=== STEP 3: PRESSURE CONTROL SETTINGS ===
If using a pressure control mode (suction or discharge), step 3 will specify some additional settings.


* Pre-catalyst thermocouple
The High and Low Auto RPM specify the operating range of the engine while controlling to the specified pressure. The Governor will not let the engine out of this range, even if the pressure is still too low or high. This is separate from the over- and underspeed alarms mentioned earlier, which specify the absolute min and max speed for the engine.
* Oil pressure switch


Finally, the Ignition state can be used to determine run signal, if the ignition is in a running state the signal is set to Run.
The response rate determines how fast the Governor will ramp up or down the RPM when in a pressure control mode. The default is 50 RPM/s. A lower value will result in less tight control, but more stable operation because the engine will ramp more slowly.


<nowiki>*</nowiki>Insert Image*
Note: Generally, for suction control the response rate can be lower, since a well (or upstream supply) changes pressure so slowly. For discharge control, the response rate is usually higher.
 
Run Signal Trigger Screen
 
=== ALARM SETUP ===
Up to eight (8) custom alarms can be configured on the AFRC to display within the Alarms screen (Pg. 40) or to trigger an external alarm though the error relay (terminal 6).
 
Configuring alarms is done on the Alarm Setup screen (Lite Pg. 305, Adv. Pg. 206) through the following parameters:
 
* Sensor – Input or condition to be monitored
* Only enabled sensors are available for selection
* Min – Minimum trigger value (optional)
* Max – Maximum trigger value (optional)
* Duration – Time, in seconds, for the sensor reading to either be below the minimum trigger value or above the maximum trigger value to become active
* Action – Action to take when alarm becomes active
* Warning – Displays the alarm within the Alarms screen (Pg. 40) and flashes the “Alarms” button on the footer of the display
* Shutdown – Closes the error relay (terminal 6), displays the alarm within the Alarms screen (Pg. 40), and flashes the “Alarms” button on the footer of the display
 
It is optional to select both “Min” and “Max” values, but at least one must be selected for sensor monitoring alarms. Selecting both values is available for monitoring a condition within a window, if desired.
 
<nowiki>*</nowiki>Insert Image*


Alarm Setup Screen
=== STEP 4: SENSOR SETUP (PRESSURE CONTROL ONLY) ===
If using pressure control mode, this step specifies the low and high specification of the sensor. The low value is the pressure that causes the sensor to output 4mA. The high value is the pressure that causes the sensor to output 20mA. These values should be printed on the sensor itself. For example, a suction sensor might say “4-20mA output for 0-100 PSI”. In this case enter “0” for the minimum PSI value and “100” for the maximum PSI value.


Upon selecting the necessary information, the alarm is enabled by toggling the “Enable” toggle box next to the sensor’s name.
If only one sensor type is used, the other can be left unchanged.


Note: Modifying an existing alarm requires the “Enable” toggle box to be toggled off and back on to take effect.
Note that this step is skipped if an EMIT annunciator is present, because the sensor will be set up and wired to the annunciator instead.


Note: A sensor can be placed in two alarm rows. For example, a PostCat TC alarm could be configured to shutdown at 1250, and generate a warning at 1000.
=== SETUP SUMMARY ===
The setup summary page shows a summary of all the selected settings for the Governor. If the page looks correct, the “Submit” button can be pressed to send the settings to the Governor.

Revision as of 17:48, 21 July 2022

After initial install, or when settings changes are needed, the Governor setup screens are used. The setup screens are accessed by selecting “Setup” on the Governor Home screen, then the “Governor Setup” button. An access level of Setup or higher is needed to access these screens.

STEP 1: ENGINE SETTINGS

Step 1 of governor setup specifies the basic engine settings. These are the number of flywheel teeth, the idle speed for when the panel switch is in “Idle”, and the speed alarm values. After initial setup, these settings are not commonly changed.

*Insert Image*

Setup Step 1

If an underspeed alarm is not needed, it can be set to “0”. The speed alarm will always shut down the engine regardless of the control mode or condition. If an RPM setpoint higher than the overspeed alarm is specified, the setting will be allowed, but once the engine hits the overspeed value it will be shut down.

STEP 2: CONTROL SELECTION

In step 2 of the governor setup, the setpoint type and value are specified. For the fixed speed control type, the setpoint is an engine RPM. For suction or discharge control, the setpoint is a PSI value.

*Insert Image*

If fixed speed control is selected, the setup will skip to Governor Setup Review after this step.

For pressure control modes, the control type can be "Setpoint, Deadband" or "Linear Ramp". (Note: Linear Ramp mode requires software version 848 or newer).

Setpoint, Deadband: In this mode, a pressure setpoint and deadband is given. If the pressure is outside of the range [Setpoint +/- Deadband], the speed will change (with the direction depending on if it is suction or discharge control). Within the deadband, the speed will not change. The speed will increase or decrease only until the speed hits a range limit, given on the next setup page.

Linear Ramp: For linear ramp mode, a low and high pressure will be given. Between this high and low value, the speed target will be calculated linearly with respect to the low and high operating RPM. Example setup (suction control):

  • Low pressure: 20 PSI
  • High pressure: 30 PSI
  • Low RPM: 1200
  • High RPM: 1600

In the above example, if the current suction input pressure is 25 PSI, the RPM target will be 1400 RPM.

STEP 3: PRESSURE CONTROL SETTINGS

If using a pressure control mode (suction or discharge), step 3 will specify some additional settings.

The High and Low Auto RPM specify the operating range of the engine while controlling to the specified pressure. The Governor will not let the engine out of this range, even if the pressure is still too low or high. This is separate from the over- and underspeed alarms mentioned earlier, which specify the absolute min and max speed for the engine.

The response rate determines how fast the Governor will ramp up or down the RPM when in a pressure control mode. The default is 50 RPM/s. A lower value will result in less tight control, but more stable operation because the engine will ramp more slowly.

Note: Generally, for suction control the response rate can be lower, since a well (or upstream supply) changes pressure so slowly. For discharge control, the response rate is usually higher.

STEP 4: SENSOR SETUP (PRESSURE CONTROL ONLY)

If using pressure control mode, this step specifies the low and high specification of the sensor. The low value is the pressure that causes the sensor to output 4mA. The high value is the pressure that causes the sensor to output 20mA. These values should be printed on the sensor itself. For example, a suction sensor might say “4-20mA output for 0-100 PSI”. In this case enter “0” for the minimum PSI value and “100” for the maximum PSI value.

If only one sensor type is used, the other can be left unchanged.

Note that this step is skipped if an EMIT annunciator is present, because the sensor will be set up and wired to the annunciator instead.

SETUP SUMMARY

The setup summary page shows a summary of all the selected settings for the Governor. If the page looks correct, the “Submit” button can be pressed to send the settings to the Governor.

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