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INSTRUCTION MANUAL: IM 1347/1

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

Guidance For Use Of This Manual ......................................................................................................... 9

1.2

Texcel Control system specifics ............................................................................................................... 9

INSTALLATION PROCEDURE ......................................................................... 10

2.1

PC (User Interface Processor - UIP) ..................................................................................................... 10

2.2

Texcel Controller (Real Time Processor - RTP) .................................................................................. 11

2.3

Texcel In-Cell Equipment ...................................................................................................................... 12

2.4

Texcel System Start-up Procedure ........................................................................................................ 12

THE SYSTEM CONFIGURATION MENU .......................................................... 13

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

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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

Copyright Froude Hofmann

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

Adjusting the coefficients ................................................................................................................. 75


Zero Button ....................................................................................................................................... 75
Reset Button ..................................................................................................................................... 75
Completing the tuning procedure...................................................................................................... 75
PID Coefficient Tuning .................................................................................................................... 75
Hydraulic Dynamometer Water Flow Considerations ...................................................................... 76
Initial Settings ................................................................................................................................... 77
Dynamometer Control Tuning Procedure ......................................................................................... 77
Throttle Control Tuning .................................................................................................................... 78
Initial Settings ................................................................................................................................... 78
Throttle Control Tuning Procedure ................................................................................................... 78
Alternate method for tuning the PID Controller ............................................................................... 78
Initial Tuning of the PID Coefficients .............................................................................................. 79
The Ziegler-Nichols PID Tuning Aid ............................................................................................... 79
Final Tuning of the PID Coefficients................................................................................................ 80
Inlet Valve Configuration (Hydraulic Dynamometers Only) ........................................................... 83
Configuring Inlet Valve Control ....................................................................................................... 84
Using Inlet Valve Control ................................................................................................................. 84
The Cross-Coupling Effect of Control Mode Pairs........................................................................... 86
PID Tuning Summary ....................................................................................................................... 87

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

CONFIGURATION OF ANCILLARY DEVICES ................................................. 90

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

AVL Smoke Meter .................................................................................................................................. 92

4.3

FG100 Fuel Meter ................................................................................................................................... 92

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

ACCESS LEVELS ........................................................................................... 104

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TEXCEL SOFTWARE

INTRODUCTION

5.1

Instrumentation Package (User Interface Processor - PC) ............................................................... 104

5.2

Texcel Controller (Real Time Processor RTP)................................................................................ 104

UTILITIES MENU ............................................................................................. 105

6.1
Printer Set-up ........................................................................................................................................ 105
6.1.1
Installing a Printer........................................................................................................................... 106
6.1.2
Uninstalling a Printer ...................................................................................................................... 107
6.2

Windows Explorer ................................................................................................................................ 108

6.3

VME Monitor........................................................................................................................................ 109

6.4

Probe ...................................................................................................................................................... 109

DATA MANAGEMENT .................................................................................... 110

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

GENERAL NOTES ON USE OF THE TEXCEL SYSTEM ............................... 117

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

GLOSSARY ..................................................................................................... 127

9.1

General Terms ...................................................................................................................................... 127

9.2

User Interface Related Terms .............................................................................................................. 128

Copyright Froude Hofmann

INTRODUCTION

10

IM 1347/1 ISSUE 5

SUPPORT DATA .......................................................................................... 130

10.1 Temperature Conversion Table C F ........................................................................................... 130


10.1.1
PT100 Platinum Resistance Tables ................................................................................................. 131
10.1.2
K Type Thermocouple Tables ........................................................................................................ 133
10.1.3
J Type Thermocouple Tables .......................................................................................................... 136
PC Serial Port Pin Connections....................................................................................................................... 139
10.2 General Texcel Controller Data .......................................................................................................... 139
10.2.1
Environment (Temperature / Humidity) ......................................................................................... 139
10.2.2
Electrical Supply ............................................................................................................................. 139
10.2.3
SCC Board Specification ................................................................................................................ 139
10.2.4
PSC Board Specification ................................................................................................................ 140
10.2.5
ECC Board Specification ................................................................................................................ 140
10.2.6
HRC Board Specification ............................................................................................................... 141
10.2.7
SBB Board Specification ................................................................................................................ 141
10.2.8
PMF Board Specification................................................................................................................ 141
10.2.9
DX100 Specification ...................................................................................................................... 142
10.2.10
Cell Interface Details .................................................................................................................. 142
10.2.11 ............................................................................................................................................................ 142
10.2.12
Transducer Box Details .............................................................................................................. 143
10.2.13
Engine Services Box (Optional) ................................................................................................. 143

11

TEXCEL V12 SYSTEM INFORMATION ....................................................... 144

11.1 DX100 Module ...................................................................................................................................... 144


11.1.1
Addressing ...................................................................................................................................... 144
11.1.2
Replacing a DX100 Controller Module .......................................................................................... 144
11.1.3
Upgrading the .mce Configuration file ........................................................................................... 145
11.2 CAN Communications.......................................................................................................................... 145
11.2.1
Checking the CAN Communications.............................................................................................. 145
11.3

CAN Pressure Transducers ................................................................................................................. 146

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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

Copyright Froude Hofmann

INTRODUCTION

IM 1347/1 ISSUE 5

Figure 6-5 registry search options __________________________________________________________


Figure 6-6 Registry Editor ________________________________________________________________
Figure 6-7 Example VME monitor display ____________________________________________________
Figure 6-8 Example Probe display __________________________________________________________
Figure 7-1 Directory structure _____________________________________________________________
Figure 7-2 Example directory listing ________________________________________________________
Figure 7-3 file handler installation _________________________________________________________
Figure 7-4 File handler start-up options _____________________________________________________
Figure 7-5 File handler confirmation dialog __________________________________________________
Figure 7-6 File handler directory structure ___________________________________________________
Figure 7-7 Main file Handler display ________________________________________________________
Figure 7-8 Configure power unit transfer ____________________________________________________
Figure 7-9 Configure Sequence transfer _____________________________________________________
Figure 7-10 Configure alarm file transfer ____________________________________________________
Figure 7-11 Configure test results transfer ___________________________________________________
Figure 7-12 Example configuration for file transfer to host ______________________________________

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108
109
109
110
111
111
112
112
113
113
114
114
115
115
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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

Initial version created from IM1344

IM1347

July 2004

Updated for software version 6.21D


onwards.

IM1347

April 2005

Updated for software version 6.30


and V10 details added.

IM1347/1

June 2005

Change of Company Name

IM1347/1

April 2008

Added Texcel V12

IM1347/1

June 2009

Added Electronic Throttle


configuration details

Copyright Froude Hofmann

INTRODUCTION

IM 1347/1 ISSUE 5

1 INTRODUCTION
1.1

Guidance For Use Of This Manual


This manual covers the various configurations required to set-up, calibrate and maintain the
Texcel Control System (software version 6.30 onwards) irrespective of the hardware platform in
use. For software versions below 6.303 please refer to issue 2 of this manual.
There are five levels of password access privilege to the system with varying degrees of
capability. Most of the areas covered in this manual require the Instrumentation level access.
Operator

Able to make temporary changes to operational parameters such as


alarms, control set points, test related information.

Team Leader

Able to oversee operator functions and has access to functions for day-today running.

Supervisor

Able to configure operational data such as automatic test schedules,


alarms, power units and test data results.

Instrumentation

Able to configure and calibrate instrumentation, graphics display pages,


maintenance and commissioning level functions.

Froude

Able to perform advanced diagnostics functions under instruction from


Froude Hofmann personnel only.

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

Texcel Control system specifics


The Texcel software is designed to support a number of different hardware platforms and is
common across the Texcel V4 PLUS, V4 Advantage, V6, V8, V10 and V12 range of controllers.
Certain items are enabled dependent on the controller type and certain details will change for
specific hardware platforms, where necessary these items are highlighted in the text.
In general where the text refers to the Front Panel this can be a Desktop Module, a front panel
mounted on the control rack, a Manual Desktop Controller or the Manual Control Panel driven
through the user interface PC. Irrespective of the control system variant each of the front
panels have common controls.

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

PC (User Interface Processor - UIP)


Unpack the PC components, associated support disks, CD-ROMs and manuals. Check that the
following items are present to satisfy software-licensing requirements

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 Controller Name

Connection Point reference

Texcel V4 PLUS

COM 2

Texcel V4 Advantage

COM 2

Texcel V6

Serial Port 2

Copyright Froude Hofmann

INSTALLATION PROCEDURE

IM 1347/1 ISSUE 5

Texcel V8

Socket marked DEBUG

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

The customer information technology department or Network System administrator


should be consulted to connect the Texcel PC to the company facility network

Texcel Controller (Real Time Processor - RTP)


Refer to the contract specific drawings (these are supplied in A3 form and are normally located
at the rear of the IM1346 Texcel Software Operator's Guide).
Connect the mains lead to the Texcel Controller unit do not power up yet. This unit may be
supplied as a desktop Diplomat style case or as a 4 or 6U rack mounting into an
instrumentation panel. The unit is normally pre-configured at Froude Hofmann UK for the
correct voltage line input.
The manual control panel is supplied in two possible options an integral panel normally
mounted on the front of the Texcel Controller rack or a stand-alone Desktop Controller.
For the Texcel V6 Manual Desktop Controller, connect the loom to its rear high-density
connector (make sure the latches lock into place). Plug the other end into the Cell Interface
panel on the rear of the Texcel Controller unit.
For the case of Texcel Advantage and V10 Manual Desktop Controllers, each end of the loom
is terminated in a 25-way D type connector. Connect one end of the loom to the Controller and
the other to the MDC Interface Panel. Ensure that the locking screws are tightened once the
loom has been connected.
For the Texcel V12 Manual Desktop Controller, connect one CAN loom from the Console to the
relevant CAN port on the Texcel Controller Unit. Connect the other CAN loom from the Console
to the relevant CAN port on the In-Cell Power Module.

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11

TEXCEL SOFTWARE

2.3

INSTALLATION PROCEDURE

Texcel In-Cell Equipment


Looms from the In-Cell dynamometer terminal box; transducer box and In-Cell box are fed from
the cell to the rear connectors on the Texcel Controller rack. Refer to the contract block
installation drawings for loom details and connection points.

2.4

Texcel System Start-up Procedure


The Texcel hardware does not have to be powered up in any particular sequence however in
the case of a Texcel V8 system the Texcel Controller (RTP) requires files from the PC (UIP) in
order to complete its start-up procedure. To ensure these files are available the UIP should be
powered on first and allowed to complete its start-up procedure before power is applied to the
Texcel in cell hardware, such as power modules etc, and then to the Texcel control rack (RTP).
The start-up Icon for the Texcel software application should not be used until the RTP has been
powered on and allowed to complete its start-up procedure (approx 30 seconds) as the disk
drive in the controller has to be accessible by the UIP for the application to operate correctly.
If an attempt is made to start the Texcel UIP application before the RTP is ready then Texcel
will make ten attempts to connect to the RTP disk. If connection cannot be established the
Texcel UIP application will terminate and the user has to start the application again.

12

Copyright Froude Hofmann

THE SYSTEM CONFIGURATION MENU

IM 1347/1 ISSUE 5

3 THE SYSTEM CONFIGURATION MENU


The Texcel control system has a number of access levels designed to inhibit unauthorised
changes to system configurations. Each access level has a password associated with it; the
following sections deal with the menu options available to users logged in at the
Instrumentation access level.
The Instrumentation access level is designed to give the user access to those functions
required to configure and calibrate the Texcel system and the tools required to diagnose a
problem should one exist.

3.1

Configure Analogue Channels


The System ConfigurationConfigure Analogue Channels option is provided to set up all
parameters associated with analogue channels. Note that this page is used to configure
analogue input and output channels including calculations, demands and ancillary device
channels.
The channel to modified is called up by pressing the Channel Select button. Each field on the
page will be enabled based on the type of channel selected. Disabled fields have the label text
colour set to grey. The hardware address is a display only field but all other fields when
enabled allow settings to be modified. Fields are modified by selecting with the mouse then
over-typing the current display value or by selecting from a drop down list box.

Figure 3-1 Configure Analogue Channels Page

Note:

June 2009

To select the current value on a drop down list, it is necessary to double click the
value.

13

TEXCEL SOFTWARE

THE SYSTEM CONFIGURATION MENU

Configuration is normally required under one of the following circumstances.

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 configuration dialog can be selected by two methods:

Selecting System ConfigurationConfigure Analogue Channels.

Selecting System ConfigurationCalibrate Analogue InputsConfigure Channel.

3.1.1 Initial Configuration Or Utilising A Spare Channel


When initially configuring a channel, or utilising a spare channel, it is first necessary to ensure
that all the hardware related parameters are correctly set, as follows:

3.1.1.1 VME Hardware board configuration - signal conditioning card channels


Note:

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.

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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

Figure 3-2 Multi Coder Link Configuration Table

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.

3.1.1.2 VME Hardware specific board configuration multiplexed channels.


These channel types are only used in the Texcel V6 & V8 hardware, there are no multiplexed
channels available in the PCI hardware used in the Texcel V4 Advantage and V10 control
systems.
These analogue input channels can be identified from the Address field of the form
MFIODX:xx:AI:yy or MFIOCX:xx:AI:yy where xx = board number and yy = channel number on
the board.
The channels on these boards require select on test resistors to be fitted. A suitable size high
precision resister is selected to optimise the gain of the channel for the expected signal range
of the transducer.

3.1.2 Software settings for platinum resistance thermometers.


For PRTs it is necessary to set the linearization type. PRTs can be linear zed to degrees
Fahrenheit, Celsius, Rankine.

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3.1.3 Software specific settings for thermocouples.


For thermocouples, the linearization must be set for the thermocouple type and the engineering
unit for display. Types J, K, R, S and T thermocouples can be linear zed to degrees Fahrenheit,
Celsius, Rankine.
Thermocouples must have their readings corrected by the temperature of the Cold junction
i.e. the terminal to which it is connected. Failure to correct for the cold junction temperature will
cause temperatures measured by thermocouples to vary as the cold junction temperature
changes.
Cold junction temperatures are measured by PRTs. The PRT adjacent to the thermocouple
terminals should be selected as the Cold Junction Compensation channel.
All other inputs should have their linearization type set to linear.

3.1.4 Completing the Initial Channel Configuration


To complete the initial configuration, the following parameters should be set:
Units - This is a six-character string and is displayed when a channel is selected onto a
display page and is a column header for logs. It is not interpreted by the system at all; hence
changing the units from Degrees C to Degrees F will not cause a channel to actually change its
display value.
Min. This field is used by display pages to set the minimum value that will be displayed on
a given item e.g. dials or bar graphs. It is normally set to the minimum value that a channel is
calibrated at, although it can be higher or lower than this value without affecting the calibration.
Max. This field is used by display pages to set the maximum value that will be displayed on
a given item e.g. dials or bar graphs. It is normally set to the maximum value that a channel is
calibrated at, although it can be higher or lower than this value without affecting the calibration.
Example.

The dynamometer torque channel may be calibrated over the range


0250Nm. Normally min would be set to 0 and max to 250, however, the min
could be set to -10, allowing zero errors to be seen.

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

A temperature input is expected to change a maximum of 2 degrees per


second. It is being scanned every 500mS, therefore the maximum expected
change per scan is 2 x 500 / 1000 = 1 degree per scan. Allowing for all
normal changes to pass unaffected the entered value should be set to 1.1.

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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.

3.1.5 Setting Alarm Related Parameters


All scanned inputs can have alarm thresholds applied to them for protecting the engine and
dynamometer when faults occur. The actual setting of the threshold is described in the IM1346
Texcel Software Operator's Guide. In addition to the threshold, the following extra
parameters control the way that a channels alarms are processed:
Alarm Dead-band - When channels cross an alarm threshold, in either direction, an alarm log
is generated. When a channels input value is at the alarm threshold, multiple alarm logs can be
generated as the input oscillates around the threshold level. These nuisance alarm logs mask
the real alarms and are best inhibited. The alarm Dead-band (hysteresis) value sets the amount
by which an input must clear a threshold by before another alarm log is triggered.
Example

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.

3.1.6 Setting Log Related Parameters


Channels can be logged during an automatic test sequence using several different loggers. The
System ConfigurationConfigure Analogue ChannelsAdd To Log option selects
whether a channel is included in the set-point log where logging is specified in automatic test
sequence stages.
If this parameter is set to YES then the current value of this channel will be logged to the setpoint log when requested. This parameter can be set to YES+LIMITS, which means that the
current value and the current alarm level for the channel will be added to the set-point log. It
should be noted that each channel has four alarm levels and each of these levels is written to
the log, The logged value of each alarm level can be useful in post processing the data as the
alarm levels can be used to produce tramlines etc on plots to show the acceptable range of the
channel.
If this parameter is set to NO then the channel is still scanned and alarmed etc but there is no
entry in the set-point log. Setting this parameter to NO does not exclude this channel from
being added into any of the other logging systems, it only excludes it from the set-point log.

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Other loggers are available as listed below:


Logger Name

Purpose

Channels Per Log

Maximum
Frequency

Set-point

General Test Log

1000

1 Hz

Periodic

Flexible/fast logging

24

100 Hz

Rolling Logger

Two speed diagnostic


logging

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.

3.1.7 Sorting log data


Data is normally logged in the order that the channels are configured in the system. Optionally,
the data can be logged in ascending parameter number order by adding the line
Sort Required = Yes
To the OUTPUT FORMAT section of the set-point.ini file using a text editor. This sets the
order of the channels in the set-point log data file, when it is generated (i.e. when the test is
run). It cannot be used to reorder existing test result files.

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.

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Figure 3-3 Calculation Editor

3.1.9 Calculation syntax


Each calculation consists of a body and a return statement. The body of the calculation
comprises statements that are evaluated in order.
Simple statements combine variables, measured parameters, constants and operators to
calculate a new value. Conditional statements perform a logical test to determine if the
following simple statements should be evaluated. Condition statements are introduced with the
if() statement and end with an endif statement. Statements can be more than a single line in
length.
Calculations must always include a return statement as the last statement, although a return
statement can also be added as the last statement of a conditional statement.

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

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CorrectionFactor1
cf
And the following are invalid variable names
1CorrectionFactor

(Starts with a numeric character)

Correction Factor

(Includes a space)

C#f

(Includes an illegal character)

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

3.1.11 Simple Operators


Simple operators perform basic mathematical operations, combining two operands to produce
a result.
Operator

Description

Example

Produces the result

Addition

3+2

Subtraction

32

Multiplication

3*2

Division

3/2

1.5

**

Raise to the
power of

3 ** 2

Figure 3-4 Calculation syntax - Simple Operators

3.1.12 Logical operators


Logical operators compare two operands and produce the logical value TRUE (that is equated
to 1) or FALSE (that is equated to 0). When performing logical tests, any value that is not 0 is
evaluated as TRUE, hence 5, 1, 5, 3.141 are all evaluated as TRUE.
Operator

Description

Example

Produces the result

<

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)

Figure 3-5 Calculation syntax - Logical Operators

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

EngineIsRunning = Speed > 50, would set the variable EngineIsRunning to 0


if Speed is less than 50 and 1 if Speed is greater than 50.

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3.1.13 Math Functions


The following math functions are also available
abs( X ) returns absolute (positive) value for X, e.g. abs(-5) returns 5.
sqrt( X ) returns square root for all positive values of X, e.g. sqrt(4) returns 2.
log10( X ) returns logarithm to the base 10 for X, e.g. log10(100) returns 2.
ln( X )

returns natural logarithm for positive values of X, e.g. ln(2.7183) returns 1.00000

3.1.14 Digital Output Control Via Calculation


Individual calculations may control a nominated digital output channel. The calculation channel
is set up to return three possible values, 0 (turn the output off), 1 (turn the output on) and 1 (do
not drive the output this allows manual override).
To map a digital to a calculation, the channel number field in the calculation address (i.e. the
calculation number, N ) is used as the Calculation N entry in the System
ConfigurationConfigure Channel MappingDigital Outputs editor. Calculation Example
5 is shown below illustrates the configuration of a calculation to control a digital output.
The simplest calculation
The simplest calculation consists of a return statement.
Return Speed * 2
Calculations of this form are normally used to convert the units of a channel e.g. from kW to
bhp.

3.1.15 Further Calculation Examples


Example 1 - Multiple operators and operands
Return Speed * Torque / 9549.3
Example 2 - Using brackets to define order of evaluation
Return (Barometric - 990) / 990
Example 3 - Multi-line expressions using variables. Variables will be automatically generated.
Temperature_Correction = Cell_Ambient - 273
Pressure_Correction = Barometric / 990
Return (Speed * Torque / 9549.3) * Temperature_Correction / Pressure_Correction
Example 4 - Using relational operators for conditional evaluation of statements
If (Cell_Ambient < 20.0)
Correction_Factor = 0.5
Elseif (Cell_Ambient > 30.0)
Correction_Factor = 1.5
Else
Correction_Factor = 1.0
Endif

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If (Barometric < 990)


Correction_Factor = 1.0
Endif
Return (Speed * Torque / 9549.3) * Correction_Factor
Example 5 Controlling a digital output
This example uses a calculation to turn a digital output (Cooling Fan) on when the engine
speed rises above 2000 rpm and off when the speed falls below this point.
To control a digital output from a calculation

Check the digital output configuration


1. Select the menu option System ConfigurationConfigure Digital Channels.
2. Set the Channel Name.
3. Configure the Sense.
4. Connect a device to the connection point specified if required. Confirm the device turns
on and off by clicking in the Current Value field.
5. Set the Current Value state to off then select Ok to exit the page.

Figure 3-6 Digital Output Configuration Page

Connect the calculation to the digital output.


1. Select the menu option System ConfigurationConfigure Channel Mapping.
2. Click the Digital Outputs button.
3. Select Mapping Channel as Calculation 6.

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4. Select Cooling Fan as Channel Name


5. Close the Channel Mapping Editor by clicking on the X exit button.

Figure 3-7 Channel Mapping Editor

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.

Load the required calculation file


1. Select the menu option Test ControlIdentify Test
2. Select the file default.clc as the Calculation Filename
3. Click on Ok to load this calculation set into memory.

Enter the calculation text.

1. Select the menu option System ConfigurationConfigure Analogue Channels.

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2. Select the calculation channel with the address SYSV:0:RU:06.


3. Change the Channel Name to Fan Selector Calc, (note that the character case must
match and a single space separates each word).
4. Click the Edit Calc button and enter the following calculation
If (Speed > 2000)
RequiredFanState = 1
Else
RequiredFanState = 0
Endif
If (requiredFanState <> currentFanState)
FanCalcResult = requiredFanState
CurrentFanState = requiredFanState
Else
FanCalcResult = -1
Endif
Return fanCalcResult
5. Select Ok to update the calculation.
6. Select Ok to close the page and apply the change.
Notes:
The first if () statement determines the required state of the digital output. In this example the
test is quite simple a more complex test could be applied at this point if required.
If a calculation returns the value 0, it will force the digital output off each time the calculation is
evaluated. If a calculation returns the value 1, it will force the digital output on each
time the calculation is evaluated.
Multiple sources (calculations, screen buttons, sequences) can drive digital outputs.
Calculations controlling digital outputs can return a third value, -1, which leaves the
outputs state unchanged. When a calculation returns 1, other controls connected to
the same output can set its state. This, for example, allows an operator, using a screen
button, to turn the fan control output on even when the engine speed is below
2000rpm.
The second if () statement determines when the outputs state needs changing by using the
variable currentFanState. Variables remember their value from the previous
evaluation of the calculation. When the requiredFanState is different to the stored
currentFanState the calculation sets the digital output state and updates the stored
value.
To test the calculation
1. On the instrumentation page, select the Fan Selector Calc channel onto a digital
display item the channel value should read 1.

Figure 3-8 Digital Display

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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.

3.1.16 Triggering Calculations From Set-point Logger


A calculation can be evaluated on a set-point log trigger by pre-configuring the channel
Address in the instrumentation file. This may be useful to prevent skew in the logged data
values where input channels and calculations may be evaluated at slightly different times
leading to discrepancies. (Note that the Scan Rate for each channel concerned should also be
optimised).
Select UtilitiesWindows Explorer then edit the \Config\Vme.ini file. Search for the
required calculation channel using the display name. Adjust the Address for the channel
substituting LU for the RU portion of the address string. Repeat this procedure for all
calculations that are required to be evaluated on a set-point log trigger. Close and save the file
(text format). Select ExitRestart The Texcel Controller.
Example
To evaluate the Power calculation each time a set-point log is triggered, the following
modification is applied (as shown in bold)
[Channel146]
ChannelType = SysVarChannel
Source Name = Channel 146
Username = Power
Max = 1000
Units = Kw
Decimal Places = 1
Address = SYSV:00:LU:00
Scan Rate = 100
Override Type = None
Para Number = 1
ConnectionPointID = User Calculation
Log Group = 1

3.2

Calibrate Analogue Inputs


Analogue Input Calibration is used to correct for variations in output and gain of the transducer
and signal conditioning system. To calibrate a channel at least two simulated input values are
applied and their equivalent engineering unit values entered. The system will then apply linear
interpolation to derive engineering units for other input levels.
Note that for a transducer with a linear response only two points are necessary. For a
transducer with a non-linear response up to forty calibration points across the transducers
operating range may be taken.

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Analogue input calibration is performed using the System ConfigurationCalibrate


Analogue Inputs page shown below.

Figure 3-9 analogue channel calibration page

Thermocouples may be calibrated by using a millivolt source or thermocouple simulator to


inject the appropriate input signals equivalent to the expected operating range.
Note that only channels that are scanned using an Analogue-to-Digital Converter require
calibration using this method. These type of channels can be easily identified from the
__:AI:__ portion of the Address field. All other types of analogue channel (such as frequency
inputs) do not require calibration, scaling is achieved using the System
configurationAnalogue Input Configuration page.

3.2.1 Basic Calibration Method


The basic calibration method consists of the following steps:-

26

1.

Change the access level to Instrumentation.

2.

Select the menu option System Configuration Calibrate Analogue Inputs

3.

Select the channel to be calibrated by clicking on the Channel Name field and
selecting a channel from the Channel Select dialog.

4.

Connect the equipment being used for simulating the input.

5.

Click the Start Cal button. The Calibration Status will read Uncalibrated.

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6.

Simulate the maximum input value for the channel.

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.

Apply the minimum signal level to the channel (first point).

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

3.2.3 Changes That Require Channel Re-Calibration


A change in transducer (apart from thermocouples of the same type) normally require recalibration as most devices have slightly different response characteristics.
A replacement I/O board such as the Dyno Throttle Controller board or a Signal Conditioning
Card, etc requires the re-calibration of all channels on that particular board.
Re-calibration is necessary where the gain of a channel has been changed.

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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.

3.2.4 Changes That Do Not Require Channel Re-Calibration


The engineering range setting in the System ConfigurationConfigure Analogue Input
page for an input channel is that used for display of the channel and to limit engineering value
inputs from the keyboard into pages such as External Controller Demands, Manual
Inputs, scrolling trace configurations, etc. The calibration process allows the entry of
engineering values outside this display range. Note that a change in engineering range does
NOT require a re-calibration of the channel as long as the Units of the channel remain
unchanged.
For thermocouples or PRTs, if the Sensor Type in the System ConfigurationConfigure
Analogue Input page is changed from one temperature scale to another but the thermocouple
or PRT type remains unchanged, the channel does NOT require re-calibration. For example, a
change from K Type Celsius to K Type Fahrenheit does not require a re-calibration.
Note

On a subsequent re-calibration of the channel, the original calibration engineering


values that were entered will be prompted in the Engineering Value box. These
should be overtyped with the equivalent values in the new temperature scale or
alternative ones entered instead.

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.

3.2.5 Problems With Calibration


If the calibration is not successful, one of the following errors will be displayed.

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.

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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.

3.2.8 Calibration The ADC Input is too close to a previous point.


When one or more calibration points have been taken, this message will appear if the current
point is very close to a previous point in terms of the reading of ADC Bits. The most obvious
cause of this message is attempting to take a calibration point without first adjusting the
simulated input (or applying an equivalent change to the input signal).
If the difference in ADC Bits between the current reading and a previous calibration point is
within 10 ADC Bits, this will reject the calibration point. A further attempt at taking a calibration
point should be attempted after first adjusting the input signal level.
If the difference in ADC Bits between the current reading and a previous calibration point is
within 100 ADC Bits, this message is simply a warning the calibration point will be accepted.
If the calibration point taken is not in the acceptable range, select Abort Cal and repeat the
calibration process for the channel from the beginning.

3.2.9 Calibration Calibration for this channel has expired.


On selecting the required channel, entering the calibration page or starting up the system, this
message may be displayed if the channel in question has a calibration Due Date that has
expired. A new calibration should be performed.
Note that the Due Date field is normally only set on a channel where calibration expiration
warning is required. (If this field is blank, no check or warning message will be displayed).
When the calibration is repeated for the channel, if a Due Date was previously set, this will be
updated to point to a date in the future. The period between calibrations is set using the
UtilitiesCalibration ParametersCal. Expiration Period.
Overnight (or on a system restart) all channels that have expired calibration will be listed in the
UtilitiesView Status Messages, A warning box will be displayed highlighting channels
require calibration.

3.2.10 Diagnosing Faults On Analogue Input Channels


When diagnosing connection problems it is often useful to check the reading of the channel
with the input signal pair shorted together. (Care should be taken NOT to short any associated
excitation signals that are provided with the channel).

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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.

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Reconfiguring a thermocouple in the System ConfigurationConfigure Analogue


Channels page to use a different temperature scale does not require re-calibration of the
channel. For example a K type thermocouple can be adjusted from C to F without affecting
the calibration the channel should read correctly for a given temperature at the transducer.
However, altering the type of thermocouple does require the re-calibration of the channel.
Note: Unused analogue signal input pairs should be shorted to prevent the introduction of
noise to the system. For example, unused thermocouple inputs may have a blanking
plug inserted in the transducer box socket.

3.2.11 Calibration Examples


The following section provides examples of calibrating various types of input.

3.2.12 Dynamometer torque calibration (all dynamometers except AC range).


The dynamometer torque input should be calibrated with the dynamometer cooling water
flowing. The calibration arms should be attached to the dynamometer. The arms and weight
pans must be free of any obstructions and must not touch the dynamometer carcass at any
point other than the mounting plate.
If the Torque signal is unstable (during and after calibration) this may indicate:

Electrical noise (dyno cables running near power cables)


That the cable shielding is poor or not connected (EMC gland)
That the weight pans are swinging on the calibration arms
The dynamometer is not stationary
The dynamometer cooling water is oscillating the load cell

1.

Select the menu option System Configuration Calibrate Analogue Inputs

2.

Select Torque from the Channel Select dialog.

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.

Enter the Maximum torque value.

6.

Click the Ok button to return to the calibration page.

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

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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).

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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.

Click the Start Cal button.

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.

Click the End cal button.

15.

Remove the calibration weights from the load arm.

16.

Optionally, some filtering may be applied if necessary. Select the Configure


Channel button; enter a Filter Factor between 0.1 and 0.2. Press Ok to return to
the calibration page.

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.

The calibration certificate shown below demonstrates a bi-directional load cell


calibration check. Five checkpoints were taken loading the dynamometer and rechecked when unloading the dynamometer. Five further points were taken when
loading the dynamometer on the opposite arm and re-checked on unloading. Note
that the load arm display window shows the equivalent mass M for the current
checkpoint Engineering Value entry (whilst this window overlays the check
calibration certificate it is not included in print-outs).

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Figure 3-10 Check calibration page

3.2.13 Cold Junction Reference Calibration (non Texcel V12 Systems)


1. Select the Cold Junction channel on the Calibrate Analogue Inputs page.
2. On the Signal Conditioning Marshalling Module, the links on LK1 should be set in A
and B positions.
3. Move the link from B position to C.
4. Click on the Start Cal button.
5. Enter 0 in the Engineering Value field.
6. Click on the Accept Point button.
7. Move the link from position C to position D.
8. Enter 66 in the Engineering Value field.
9. Click on the Accept Point button.
10. Click on the End Cal button.
11. Move the link from position D to position B.
12. Confirm that the Current Value field reads the ambient temperature for the test cell.

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3.2.14 Cold Junction Reference Calibration (Texcel V12 Systems)


1.

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.

Figure 3-11 LK3 on DX100 module

2.

Select the Cold Junction channel (DI0:01:AI: 47) on the Calibrate Analogue Inputs
page.

3. On the Signal Connector Board, put a link on LK1 in position B (0 degrees C)

Figure 3-12 LK1 on Signal Connector Board

4. Click on the Start Cal button.


5. Enter 0 in the Engineering Value field.
6. Click on the Accept Point button.
7. Move the link from position B to position C (66 degrees C)
8. Enter 66 in the Engineering Value field.
9. Click on the Accept Point button.
10. Click on the End Cal button.
11. Move the link from position C to position A.
12. Confirm that the Current Value field reads the ambient temperature for the test cell.

3.2.15 Thermocouple Inputs


Thermocouple inputs are most easily calibrated using a thermocouple calibrator, which
provides compensated mV, connecting to the system using the socket that the thermocouple
is connected to. The calibrator must be connected to the input using the correct type of
compensating cable for the thermocouple being calibrated.
Thermocouple inputs should be calibrated for the expected range of the input parameter, which
is usually less than the full range capability of the transducer.

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0 150 for liquids (oil, engine coolant, fuel, etc).


0 1200 for exhaust gasses
0 60 for air temperatures

E.g.

3.2.16 Thermocouple Calibration (Millivolt Method)


1. Select a temperature (K type) channel (e.g. Oil Temp).
2. Click on the Configure Channel button.
3. Click on the Cold Junction Channel field.
4. Select Not compensated from the drop down list (note the previous setting for this
field).
5. Click on the Exit button to return to the calibration screen.
6. Connect a mV source in place of the thermocouple input using copper cable.
7. Set the input signal to 0 mV.
8. Enter 0 in the Engineering Value field.
9. Click on the Accept Point button.
10. Change the input signal to the value corresponding to the maximum input value (shown in
Table 3).
11. Enter the maximum input value in the Engineering Value field.
12. Click on the Accept Point button.
13. Click the End Cal button.
14. Click on the Configure Channel button.
15. Click on the Cold Junction Channel field.
16. Select the original setting for this channel from the drop down list.
17. Click on the Exit button to return to the calibration screen.

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:

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3.2.17 Thermocouple Calibration (Compensated Method)


Note:

Do not attempt this calibration until the Cold Junction channel has been calibrated.

1) Select a temperature (K type) channel (e.g. Oil Temp).


2) Connect a thermocouple simulator in place of the thermocouple input, using compensating
cable.
3) Set the input signal to simulate 0 Degrees C.
4) Enter 0 in the Engineering Value field.
5) Click the Accept Point button.
6) Change the input signal to simulate the value corresponding to the maximum input value.
7) Enter the maximum input value in the Engineering Value field.
8) Click the Accept Point button.
9) Click the End Cal button.

3.2.18 Pressure/Linear Calibration


1) Select a pressure channel (e.g. Oil Pressure).
2) Connect a calibrated pressure pump to the input.
3) Set the pressure to the minimum pressure value for the channel.
4) Enter the minimum pressure value in the Engineering Value field.
5) Click the Accept Point button.
6) Change the pressure to the maximum pressure value.
7) Enter the maximum pressure value in the Engineering Value field.
8) Click the Accept Point button.
9) Click the End Cal button.

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3.2.19 The Calibration Report.

Figure 3-13 Calibration Report

In the System ConfigurationCalibrate Analogue Inputs page, if the selected channel


reads Calibrated the Check Cal Report feature becomes available. Press the Check Cal
Report button to display the current check calibration certificate for the current channel.
The calibration report is used to provide a permanent record of a calibration. Where a printer is
available, a hard copy of the calibration certificate can be requested using the Print button.
It is recommended to confirm the accuracy of a channel calibration by entering calibration
check-points. This is similar to actually performing the calibration except that more points can
be recorded than are required for calibration. For most transducers such as temperature
thermocouples, 10 points including the calibration points are sufficient to prove the accuracy of
the calibration. For a Torque calibration it is suggested that more points are taken when
loading and unloading the dynamometer.
The top section records the cell details selected in the UtilitiesCellID box such as the cell
number and company logo. Where check calibration points have been taken the Check Cal
Status will either display Pass or Fail depending on whether all calibration points are within
acceptable tolerance.
The middle sections list the details entered in the System ConfigurationConfigure
Analogue Channels and System ConfigurationCalibrate Analogue Inputs pages for the
associated channel such as the engineering range and input transducer type.

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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% =

Engineering Valueentered - Engineering Valuecalcualted


Engineeringmax Engineeringmin

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

Calibrate Analogue Outputs


Analogue output calibration is required to correct the inherent errors in the output channel
produced by component tolerances, mechanical or electrical actuator characteristics. The
Texcel system implements span and offset correction in software derived from a simple linear
two-point calibration.
Normally, analogue output calibration is only required at initial system commissioning time or if
the board containing the output channel is replaced due to failure. Optionally, the customer may
elect to check or re-calibrate all outputs every 6 to 12 months as required. Analogue Outputs in
the system can be identified using the UtilitiesSensor Connection List

Figure 3-14 Sensor Connection list

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Analogue outputs require a minimum amount of configuration using the System


ConfigurationConfigure Analogue Channels. Click on the Channel Select button to
locate the channel required. The engineering units and range are specified to match the
channel output, all other fields are optional.

Figure 3-15 Configuring Analogue Output Channels

Press Ok to save the changes in configuration or select an alternative channel to modify.

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3.3.1 Analogue Output Calibration Procedure


Set-up and adjustment of the output transducer and all associated mechanical components
should be made prior to calibrating the output channel.
Select the Output Calibration page at supervisor level access using the System
Configuration Calibrate Analogue Outputs option.

Figure 3-16 Analogue Output calibration page

The procedure to calibrate and output is as follows:

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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.

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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.

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3.3.2 Analogue Output Calibration Examples


3.3.3 Example 1: Water Control Output (E to P converter).
Note:

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.

Click the Start Cal button.

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.

Click the Accept Point button.

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.

Click the Accept Point button.

7.

Click the End Cal button.

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.

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3.4

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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.

3.4.1 Electronic Calibration of the Throttle Actuator


Calibration of the throttle actuator requires two levels of calibration.

Initial calibration of the electronics and mechanical set-up of the throttle actuator (normally
at commissioning time only)

Re-calibration on a change of engine.

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.

3.4.1.1 Prove In-Cell Box Power Module Throttle Output Stage


1.

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.

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Press the throttle actuator thermal trip (i.e. disable the throttle actuator red button).

3.4.1.2 Throttle Analogue Output Calibration


1.

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.

Press the RUN button, which should now stay illuminated.

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.

On the Texcel User Interface PC, select the System ConfigurationCalibrate


Analogue Outputs page, click on the Channel Name field and select the Throttle
Ctrl Op channel.

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.

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3.4.1.3 Throttle Feed-back Analogue Input Calibration


1.

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.

Connect a voltmeter to terminals 11 and 12 on the throttle actuator terminal block.


Check the excitation voltage is 5V (20mV).

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.

Adjust the MIN potentiometer on the servo board to 0V at TP3 (5mV).

7.

On the Texcel User Interface PC, select the System ConfigurationCalibrate


Analogue Inputs page, click on the Channel Name field and select the Throttle
Position channel.

8.

Click on the Start Cal button then click the Accept Point button for the first
calibration point.

Figure 3-17 Analogue Input Calibration Page

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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.

3.4.1.4 Dynamic Tuning of the Throttle Servo Loop


1.

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.

Select the UtilitiesCalibration Parameters option. Set the Minimum Position


to 40%, Maximum Position to 60% and Time Period to 1 second.

5.

On the Texcel User Interface PC, select the System ConfigurationCalibrate


Analogue Outputs page. Press the Test button

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.

In the Calibration Parameters window set Minimum Position to 50% and


Maximum Position to 51%. Check that a change in signal is still visible on the
oscilloscope and the Throttle Position channel registers a change in reading
(although this is unlikely to be a 1% change). If there is no detectable change, make
small re-adjustments to VR3 and VR4 potentiometers as necessary.

9.

Press Stop Test then Ok to exit the calibration page.

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.

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3.4.2 Mechanical Set-up of the Throttle Actuator


This procedure is performed for either a change of engine or a change of throttle body
assembly.
To obtain the best resolution from the actuator it is necessary to set the ninety-degree arc of
the throttle actuator lever to be approximately equal to the mechanical travel of the throttle
linkage. This is achieved by disconnecting the throttle linkage and adjusting the mechanical
travel of this linkage to match as close to the maximum range of the actuator.
For further details on the throttle actuator, refer to IM1320 TX21 Throttle Actuator Manual.
Warning: Use of the In-Cell Box key-switch will cause rapid movement of the throttle
actuator and linkage if attached. Confirm that all personnel are clear of the
actuator and associated moving parts before using this facility. Note that
the instructions in the following sections should be followed to avoid
mechanical damage to the actuator and/or engine throttle mechanism.

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.

Confirm the fuel feed to the engine throttle is shut off.

2.

Press the throttle actuator thermal trip (i.e. Disable the throttle actuator red button)

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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.

Disconnect the linkage at the engine or actuator side.

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

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8.

Move the actuator arm against the minimum end stop.

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

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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.

3.4.2.1 Re-adjusting the Throttle Servo Circuit


1.

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.

3.4.2.2 Checking the Min and Max Positions


1.

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.

Press the RUN button, which should now stay illuminated.

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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.

Press the Stop button.

12.

Now check the Throttle Calibration refer to Section 3.5.5

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.

3.4.3 Calibrating Dynamometer Demand for an Eddy Current Dynamometer


When calibrating the dynamometer demand on an eddy current dynamometer, it is the field
excitation current that must be calibrated, not the voltage. Note that an EC dynamometer
requires a non-zero minimum current for correct operation.
1.

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.

Press the RUN button, which should now stay illuminated.

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.

Click the Start Cal button.

6.

Adjust the DAC Output until the ammeter displays 50 mA (+/-30mA).

7.

Click the Accept Point button.

8.

Adjust the DAC Output until the ammeter reads 5.0 A.

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.

Click the Accept Point button.

10.

Click the End Cal button.

11.

Fill in the calibration details in the centre fields for any equipment used

The Dyno Ctrl Op channel is now calibrated.

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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.

3.5.1 Calibration of the Throttle Actuator


Calibration of the throttle actuator
consists of two parts.

Mechanical set-up of the throttle actuator.

Throttle actuator Learn procedure.

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.

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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.

Confirm the fuel feed to the engine throttle is shut off.

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

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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.

Disconnect the linkage at the engine or actuator side.

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.

Move the actuator arm against the minimum end stop.

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.

Move the throttle actuator arm to the maximum position.

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.

The Throttle Pos Cal OK channel will be energised.

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.

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3.5.2 Checking the Min and Max Position

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.

Press the Enabled pushbutton on the Manual Control Panel.

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.

3.5.4 Calibrating Dynamometer Demand for an Eddy Current Dynamometer


When calibrating the dynamometer demand on an eddy current dynamometer, it is the field
excitation current that must be calibrated, not the voltage. Note that an EC dynamometer
requires a non-zero minimum current for correct operation.

54

1.

Ensure the Dyno Water Pressure digital input is ON (ELMO committed I/O).

2.

Ensure the Dyno Enable digital output is ON (ELMO committed I/O).

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.

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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.

Click the Start Cal button.

10.

Adjust the DAC Output until the ammeter displays 50 mA (+/-30mA).

11.

Click the Accept Point button.

12.

Adjust the DAC Output until the ammeter reads 5.0 A.

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.

Click the Accept Point button.

14.

Click the End Cal button.

15.

Fill in the calibration details in the centre fields for any equipment used
The Dyno Ctrl Op channel is now calibrated.

3.5.5 Checking the Throttle Calibration


With the manual control panel Reset and Run buttons on, the throttle may be driven from the
manual control panel throttle demand control. To check the calibration of the throttle output and
feedback channels, use the System ConfigurationCalibrate Analogue InputsCheck
Cal Report. Check calibration is performed as follows
1.

Select the Throttle Position channel in the System ConfigurationCalibrate


Analogue Inputs page. If the channel Status is Calibrated, press the Check Cal
Report button.

2.

Enter a Permitted % Error of 0.5%.

3.

If a previous check calibration exists, press the Clear All button.

4.

Enter an Engineering Value of 0 (in the blue entry box).

5.

Select the Test ControlDemand Control box. Change to Position control mode
on the throttle. Enter a throttle demand of 0%.

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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.

Enter an Engineering Value of 10 (in the blue entry box).

8.

Select the Test ControlDemand Control box. Enter a throttle demand of 10%.

9.

Press the Accept button, confirm the checkpoint passes.

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.

Figure 3-20 Check Calibration Report

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Configure Digital Channels


This option is chosen to modify the software processing performed on the systems digital inputs
and outputs. Selecting it displays the dialog shown below.

Figure 3-21 Configure Digital Channels Dialog

3.6.1 Digital Input Configuration


Texcel uses digital inputs to control certain actions, for example to silence the alarm klaxon, or
to trigger alarms that can alert an operator or shutdown the engine.
Configuration is normally required when the system is configured or if digital input is added to
the system. To configure a digital input
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 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.

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3.6.2 Digital Output Configuration


Texcel digital outputs are controlled by events within the system, for example an engine crank
request or speed falling below idle speed. Digital outputs can also be controlled from on screen
pushbuttons, via calculations or from the automatic test sequencer.
Configuration is normally required when the system is initially commissioned or if a digital
output is added to the system. To configure a digital output

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.

Configure External Controllers


Texcel provides 12 external PID controllers for customer use. Applications of the controller
include, but are not limited to

Engine Coolant Temperature Control

Engine Oil Temperature Control

Cell Ambient Air Temperature Control

Exhaust Back Pressure Control

Generally, the controllers can be configured to control any parameter provided that

There is a suitable method of measuring the parameter value

There is a suitable actuator for controlling the parameter

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.

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Servo Channel Inlet Channel

Outlet Channel

Demand
Actuator

Engine

Pipe Temp
Loss

Control

Eng Temp Rise

Schematic diagram for External controllers


Figure 3-22 External Controller Schematic

3.7.1 Example 1: Control of Engine Cooling Air Speed.


A fixed speed fan provides the cooling air. The blade pitch is controlled by air pressure, where
increasing the air pressure decreases the blade pitch and hence the cooling air speed (hence
the system is fail safe, loss of air pressure causes full cooling to be provided). The air speed is
measured by a pitot tube, whose output is 0V at minimum air speed and 10V at maximum air
speed, providing the feedback signal. The controlling air pressure must therefore be decreased
if the feedback decreases.

3.7.2 Example 2: Engine Coolant Temperature Control.


Normally it is required to control the engine coolant temperature as it leaves the engine. This
temperature is typically controlled by adjusting the flow of cooling water passing through the
engine coolant heat exchanger.
The engine coolant is then piped to the engine, where its temperature falls further and then
passes through the engine, where its temperature rises. By allowing for these effects, the
required coolant water temperature at the heat exchanger to give the demanded engine coolant
outlet temperature can be calculated. Because this temperature is measured closer to the
actuator, the response time is faster and control is more accurate.
The controllers are enhanced by providing multiple (three maximum) feedback loops, which can
improve control performance where there are time delays and changes in the controlled
parameter and the actuator output.

3.7.3 Theory of operation


The controllers are three term PID controllers, where the error between the control set-point
and the servo feedback channel is used to correct the controllers output, thus maintaining the
controlled parameter at the required value.
The controller output value ranges from 0 to 1, with 0 representing one end of the control
actuators travel and 1 representing the other end. The analogue outputs are hardware
selectable between 010Volts or 420mAmps.
The controller can be configured to work with actuators whose control action is reversed.

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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

This is not failsafe.

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.

3.7.4 External Controller Configuration


The configuration process is required to ensure the correct operation of the controller. The
following steps are required:
1.

Identify and set up the controller actuator output.

2.

Identify and set up the controller inputs

3.

Tune the controller parameters to optimise performance

The first two steps are normally only required when setting up a new controller.

3.7.5 Starting the external controller configuration dialog


The external controller configuration dialog is started by selecting the System
ConfigurationConfigure External Controllers option.

Figure 3-23 External Controller Demand Dialog

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Click the Configure button for the required controller. This will launch the controller
configuration dialog shown below.

Figure 3-24 External controllers configuration dialog

3.7.5.1 Overview of external controller configuration dialog


The External controller configuration dialog can be divided into six main areas:

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.

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3.7.6 Setting up the controller actuator output


Each controller is factory configured to an analogue output on the system. This can be
identified from the Output Address field on the controller configuration dialog. The actuator
for the controller should be connected to this output and it should be calibrated for the required
actuator range.

3.7.7 Setting up the controller inputs


Clicking the Configure Inputs button on the External controller configuration dialog
displays the Configure Inputs Dialog for selecting the controller inputs, shown below.
There are four inputs that can be configured, as follows:

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.

3.7.8 Setting the controller coefficients


Before setting the controller coefficients, the controller analogue output and inputs must have
been correctly set up. The controller set up procedure is iterative, with the controller coefficients
being adjusted and the effects of the changes being monitored.
The normal procedure for initially setting up the controller is:

62

1.

Set the controller update rate

2.

Set the integrator range

3.

Disable the integrator.

4.

Initialise the Proportional term

5.

Run the system and optimise the proportional and I Max terms

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Optimise the Integral Time

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.

3.7.8.1 Setting the controller update rate


The controller update rate should be set to match the servo feedback bandwidth. If the
controller is set too slow it will not respond to input changes. If the controller is set too fast, the
integrator and differentiator will not be calculated properly as they will be working on false
errors. The update rate should be set no faster than the scan rate on the servo feedback
channel (For temperature channels measured with a thermocouple or PRT, this should not be
faster than 2Hz).

3.7.8.2 Setting the integrator range


Providing that the analogue output has been correctly calibrated against the servo actuator, the
integrator minimum should initially be set to 0.0 and the integrator maximum should be set to
1.0

3.7.8.3 Disabling the integrator


The integrator time should be set to at least 10 times the expected response of the system.
Example: If it expected that a temperature will stabilise in 100 seconds, then the integrator
should be set to 1000 seconds. If it is not possible to calculate a suitable value, then
set the integrator time to 1000.

3.7.8.4 Initialising the proportional term


The proportional coefficient should initially be set to give a 1% actuator movement (0.01
controller output) for the maximum allowed system error.
Example: The maximum allowed error is 2 Degrees C. The proportional coefficient should be
initialised to 0.01 / 2 = 0.005.

3.7.8.5 Tuning the proportional and I Max terms


Run the system in an appropriate condition for the controller to operate.
Example: For the engine coolant controller, run the engine at a suitable speed / torque setting
to cause its water to heat above the controller demand.
Check that the integral and feed forward outputs are 0.0 and that the Proportional Output is
negative and decreasing towards 0.0 as the feedback value approaches the demand. Check
that the Output Value is 0.0
Check that when the error goes positive, the Proportional Output goes positive and the Output
Value tracks the Proportional Output. If there is an actuator feedback channel, check that the
actuator is tracking the control output.

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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.

3.7.8.6 Tuning the integral time


When the proportional and I Max terms have been tuned, the integral time can be reduced to
improve the steady state accuracy. Adjust the demand and measure the time until the servo
feedback value first reaches the new value. Set the integral time to 5 times this value.
Check that the Integrator Value increases towards the Output Value and the Proportional
Output and Error values decrease. Check that the system remains stable.
Further reduce the Integral Time in 20% steps until the system becomes unstable, reducing it
back to the last stable value.

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3.7.8.7 Reverse Action Control


If reverse action control is required, the above procedure is still used, with the exception that
the proportional term should be set to a negative value and references to values increasing and
decreasing should be reversed (i.e. increasing becomes decreasing).

3.7.9 Special Applications for External Controllers


The external controllers can use any channel defined in the system for the feedback channels.
By using the calculation channels, the controllers can be configured for a wide range of
applications. Some examples of how the controllers can be used are given below.

3.7.9.1 Open Loop Control


Open loop control is used where there is either an external controller just requiring a set-point
or where it is just required to set the position of an actuator.
For open loop control, the integrator and proportional terms should be disabled i.e. set to 0. All
input channels should be cleared. The update rate should be set at a value suitable to react to
expected demand changes.
The Feed Forward Gain Term should be set to scale the external controller demand range onto
the range 0 to 1. This is calculated by 1 / FSD where FSD is the Full Scale Deflection
(maximum value) of the input range.
Example: For an external coolant temperature controller where the demand range is 0 to 200
Degrees C, the Feed Forward Gain Term should be set to 1 / 200 = 0.005.

3.7.9.2 Input Channel Repeaters


Input channel repeaters are used when it is necessary to output measured data (E.g. Speed,
Torque, Power) as analogue voltages or currents. For input channel repeating, the integrator
and proportional terms should be disabled. The demand should be set to 0.0 and the update
rate to the required output update rate. The channel to be repeated should be selected as the
servo feedback channel and the other input should be cleared.
The Feed Forward Gain Term should be set to range the required output.
Example: To repeat the Torque output, with 100Nm represented by 10Volts, the Feed Forward
Term should be set to 1 / 100 = 0.01

3.7.10 Potential Problems With External Controllers


This section lists a few of the most common faults that occur with external controllers and the
corrective action.

3.7.11 Servo Output Fluctuation


When viewing the Controller Variables in the System ConfigurationConfigure External
ControllersConfigure page, the Output Value alternates between two or more values
when the Current Demand and Error are stable, this may indicate that more than one
controller is attempting to drive the same output channel.
Compare the Output Name with that set by all other external controllers, (select Ok then
Configure button for each controller in turn).

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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.

3.7.12 Output Driven in Reverse Direction


When viewing the Controller Variables in the System ConfigurationConfigure External
ControllersConfigure page, the Output Value drives between 0 (minimum) and 1
(maximum). Where the Output Value drives in the opposite direction to that required based
on the current demand set-point and feedback signals this might indicate the direction of action
is wrong.
There are two levels of check that are required, the output calibration and the direction of action
of the external controller.
The output calibration should be checked such that the minimum position (first calibration point)
represents the fail-safe position of the actuator / valve. Select the channel referred to in the
Output Name field in the System ConfigurationCalibrate Analogue Outputs page.
Select the UtilitiesCalibration Parameters option and set the Minimum Position and the
Maximum Position to 0%. Set the Time Period to 2 seconds. Press the Test button in the
output calibration page. The output should drive to the minimum output (i.e. the first calibration
point taken during the original output calibration for the channel). In most cases this is
equivalent to zero volts output, i.e. the fail-safe position of the actuator.
Set the Minimum Position and the Maximum Position to 100%, the actuator will drive to
the maximum output. When complete, select the Stop Test button, (this will return control of
the output to the external controller). If the actuator is moving in the incorrect direction based on
this test, re-calibrate the output.
If the output calibration test shows the actuator to be moving in the correct way, return to the
System ConfigurationConfigure External ControllersConfigure page. If the difference
between the Current Demand and Servo feedback (i.e. the Error) is positive, the Output
Value should drive towards 1 (maximum output) if the value for the Proportional term is
positive, or towards 0 (minimum output) if the Proportional term is negative. Therefore,
changing the sign of the Proportional Term reverses the direction of action of the output.
Example

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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.

Figure 3-25 Example external controller configuration

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.

Figure 3-26 Water control example

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3.7.13 Lack of Output


The minimum settings for an external controller to function are;

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.

Integrator Value Max should take a positive value, initially 1.

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.

3.7.14 Servo Output Differs When Running an Automatic Test Sequence.


Normally, when the system runs in manual control mode, the demand set-point for an external
controller is taken from the External Device Demands page.
When an automatic test sequence is run, these demands are overwritten with demands
specified in the second page of the sequence editor entitled External Devices for each stage
in the sequence. The demand set-point is applied at the start of each test stage. If the
automatic test sequence is held, the current demands will remain unchanged from those
specified in the current stage unless the manual control panel is re-enabled.
Note that with controllers that are configured to schedule the output directly from the Servo
feedback analogue input (e.g. inlet valve controller), the manually entered demand value
should always be set to zero (including the demand set-points specified in all test sequences).

3.8

Configure Control PIDs


The Texcel controller uses an enhanced three term PID closed loop controller to control both
the throttle and the dynamometer in speed and torque modes. To obtain the best response
from the controller, the control coefficients must be optimised for the engine / dynamometer
combination for each control mode being used.
Warning: The PIDs should not be tuned until the servo controller outputs and control
feedback signals have been calibrated correctly.

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

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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.

Figure 3-27 PID configuration page

3.8.1 Algorithm Description


Texcel employs the popular PID (Proportional, Integral and Differential) algorithm. A PID
algorithm divides the demand-to-feedback error into its magnitude, velocity and acceleration
components. Each component is then weighted and combined to form the control signal.
Control Signal = P * error + I *

error (dt) + D * d (error)

dt

Figure 3-28 General PID Equation

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.

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Figure 3-29 PID control schematic

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.

Figure 3-30 Proportional Term Explanation

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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:

items marked * are adjusted using software control.


Figure 3-31 PID term comparison tables

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.

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Figure 3-32 Integral Term operation

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.

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(Current error, in eng. Units last error, in eng. Units) x D


Configured system maximum
The differential time is related to the differential gain by:
Differential Time = Differential Gain x Sampling Instant (Scan Rate)
Or
Maximum Differential Time = 99.999 x 0.02.

Figure 3-33 Differential term operation

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,

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Figure 3-34 Effect of each PID term

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.

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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.

3.8.5 Adjusting the coefficients


A term is selected by clicking its associated button. Its value is then adjusted using the
Decrement or Increment buttons or by directly entering a value into the associated numeric
field. The size of the increment is set by the 10, 1 and 0.1 % buttons.
E.g. To increment that Dynamometer Proportional coefficient by 20%
1.

Click the P button in the Dynamometer Control Parameters section

2.

Click the 10 button in the Inc/Dec Value by (%) section

3.

Click the increment button twice

To set the Throttle I time directly to 2.0 seconds


1.

Click in the I numeric field in the Throttle Control Parameters section

2.

Use the Delete key to erase the current entry

3.

Enter 2.0

3.8.6 Zero Button


The Zero buttons will set the currently selected coefficient to 0.0. This will normally stabilise a
system, but care should be taken as if it is used when the selected term has a relatively large
output, the dynamometer torque or the throttle position will quickly change.

3.8.7 Reset Button


The Reset button can be used to set the currently selected coefficient back to its initial value.

3.8.8 Completing the tuning procedure


When all the required coefficients have been tuned, they can be permanently saved by clicking
the Save button. This saves ALL the coefficients.

3.8.9 PID Coefficient Tuning


The PID tuning procedure is system dependent, but the strategy described below can be used
to achieve the desire performance for the majority of applications.
It should be noted that there are conflicting requirements for good steady state performance
and good transient response and a different set of coefficients will be determined if control is
optimised for either strategy.
All configuration and calibration of the system should be completed before an attempt is made
to tune the PID coefficients.
The control mode pair of throttle in position mode and the dynamometer in speed mode is an
intrinsically stable control mode for the engine and can be used as an escape mode when

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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.

3.8.10 Hydraulic Dynamometer Water Flow Considerations


For a hydraulic dynamometer to perform correctly, it is important to ensure that its water supply
is in accordance with the specifications in its manual. The dynamometer control system works
by adjusting the dynamometer outlet valve position to maintain the correct volume of water
within the dynamometer to maintain the torque required to hold the desired set point.
Irregularity in either the water supply or drain connections will result in excessive control
corrections being required to maintain an even load on the prime mover producing variations in
the dynamometer torque.
When tuning the controllers, it is necessary to take into account any effects of the engine (e.g.
Speed control on the dynamometer against speed governed engine will not realise high
performance).
The water flow through a hydraulic dynamometer provides not only the cooling medium but also
the means by which the dynamometer applies torque to the shaft. This factor can have a
marked effect on the quality of control of the dynamometer. Some observations about water
flow and outlet valve position should therefore be considered when tuning the PID coefficients:

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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).

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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.

3.8.11 Initial Settings


When tuning a completely new installation or wishing to fully re-tune the PID coefficients, the
following initial settings should be used:
Proportional

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.

3.8.12 Dynamometer Control Tuning Procedure


1.

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.

Reduce the Integral Time to about 1.00.

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.

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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.

3.8.13 Throttle Control Tuning


Throttle control tuning is much more engine dependent and therefore more difficult to describe
generally.

3.8.14 Initial Settings


When tuning a completely new installation or wishing to fully re-tune the PID coefficients, the
following initial settings should be used:
Proportional

1.00

Integral

4.00

Differential

0.00

3.8.15 Throttle Control Tuning Procedure


Unless high performance control is required, then the easiest strategy to adopt is leaving a
fairly low Proportional coefficient and reducing the Integral Time until set-point changes are
acceptably fast.
For better performance, the Proportional coefficient will need increasing, but system stability is
often less than with dynamometer control.

3.8.16 Alternate method for tuning the PID Controller


The alternative method for tuning coefficients has three stages
initial tuning to remove uncontrollable instabilities
identification of approximate system parameters using the Ziegler-Nichols tuning method
final tuning to achieve the required level of control.

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IM 1347/1 ISSUE 5

3.8.17 Initial Tuning of the PID Coefficients


Set the Texcel controller with the dynamometer in the speed control mode. Start the engine and
then warm the engine to its normal operating temperature. It is essential that the engine is
running smoothly to achieve the optimum settings for the PID coefficients.
The throttle position and dynamometer demand should be set to achieve approximately one
third of the engines rated speed and power. If the control is unstable (visible or audible
oscillations of the engines speed and torque around the demand values) then reduce the
throttle demand to idle and adjust the current control mode pair PID coefficients as follows:

Reduce the Prop coefficient by 50% of the current setting.

Set the Int coefficient to 0.000

Set the Diff coefficient to 0.000

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.

3.8.18 The Ziegler-Nichols PID Tuning Aid


Ziegler-Nichols provides a PID tuning aid based on empirical study. The method requires the
integral and differential gains of the controller to be set to zero and the proportional gain
increased until the controlled parameter exhibits marginal stability: continuous oscillation that is
neither growing nor reducing.
The proportional gain necessary to induce this oscillation, K, and the period of the oscillation, T,
are then noted. This method is only useful for the single control modes of Throttle Position,
Dynamometer Speed, Throttle Position, Dynamometer Torque and Throttle Speed,
Dynamometer Position.
Set the I and D coefficients to 0.000, effectively the lowest integral and differential gains
possible on Texcel. Increase the P coefficient until sustained oscillations of the controlled
parameter are achieved. Quickly note the period of the oscillations and the P coefficients, then
reduce the P coefficient to restore stability.
The P, I and D coefficients can now be approximated using the following relationships:
Proportional Gain (P)

0.6 x K.

Integral Time (I)

T / 2.

Differential Gain (D)

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.

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3.8.19 Final Tuning of the PID Coefficients


It is recommended that the proportional, P, coefficient is tuned first followed by the differential,
D, coefficient. It may be necessary to return to the P coefficient for final adjustments after
tuning the D coefficient. The integral, I, coefficient should be adjusted after the P and D
coefficients have been completed; generally, the I coefficient can be adjusted independently of
the others.
When stable running has been achieved at low power settings, increase the engines throttle
setting and the dynamometers demand for the controlled parameter. Generally, as the
dynamometer shaft speed increases the speed of response of the dynamometer increases,
effectively increasing the overall gain of the Texcel and dynamometer system. It may be
necessary to reduce the P, D or both coefficients to restore stability. Reduce the engine to the
low power settings and ensure the reduction in the P and D coefficients have not degraded the
stability of the control to an unacceptable level.
The effect of the integral coefficient tends to be independent of speed.
Where an inlet valve has been fitted to a hydraulic dynamometer it may be possible to restore
stability by increasing, or decreasing the flow of water through the machine. During the final
tuning of the PID coefficients the inlet valve position used to achieve the optimum control
performance should be noted against the measured speed and torque for the full operating
range of the engine. This information will be useful when considering the configuration of the
inlet valves automatic scheduler.

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.

Figure 3-35 Proportional Gain Settings

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Figure 3-36 Optimal proportional gain example

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


LOW

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

Figure 3-37 Oscillation Frequencies

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.

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3.8.19.2

THE SYSTEM CONFIGURATION MENU

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.
.

Figure 3-38 Effects of increasing P or D term

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.

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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.

Figure 3-39 Effects of changing I term

3.8.20 Inlet Valve Configuration (Hydraulic Dynamometers Only)


Some dynamometers will be provided with inlet valves, which can be controlled from the Texcel
control systems in both manual and automatic modes. If an inlet valve has been fitted after the
dynamometer / control system has been supplied then the Texcel configuration will need to be
updated. If this is required please contact Froude Hofmann Technical support for further details.

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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.

3.8.21 Configuring Inlet Valve Control


From software version 6.30 inlet valve control is built in and there is no longer a requirement for
inlet valve to be configured by the user. If the Texcel system has been supplied with an inlet
valve already configured then no user configuration is necessary. This can be confirmed by
looking at the channel list displayed to confirm the inlet valve control channels are available.
To check the configuration click on a numeric display field to show the channel selection list for
analogue channels, if this list contains a channel name Inlet Valve Demand then the system
has been supplied configured for an inlet valve.
If the channels are not in the channel selection list then the Texcel controller is not configured
for inlet valve control, in this case please contact Froude Hofmann Technical support for details
of the configuration changes required.

3.8.22 Using Inlet Valve Control


To use inlet valve control it is necessary to have some on screen controls, these are used to
switch inlet valve control between manual and automatic and to enter the configuration details
for the valve control. All of the configuration items required are available as channels and as
such can be attached to any screen display for ease of use.
Once the configuration details have been set the only controls required on the screen for day to
day operation are a digital switch for selection of manual or automatic mode and a manual input
for the user to enter the required inlet valve demand.
A simple display panel as shown in Figure 3-40 should be created on a spare page, this will
allow the configuration details to be adjusted when required. The table shows the use and
effect of each of the configuration items.

1
2
3
4
5
6
7
8
9
Figure 3-40 Inlet valve configuration channels

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Item
Number

Name

Usage

Auto IV Control Enable

When OFF the inlet valve is controlled by the inlet valve


demand in a positional mode. I.E user enters positional
demand and the valve moves to that position irrespective
of speed.

Inlet Valve Demand

Positional demand ranged 0 to 100 %

IV Interlock Speed

This parameter sets the speed below which the inlet


valve will close to the position specified in the IV
Interlock Position field. This prevents water from flooding
the bearings when the dynamometer is at very low
speeds or stationary.

IV Interlock Position

This parameter specifies the minimum position the valve


will be set to when the speed is below the IV interlock
speed, this is usually set to ensure some water is always
flowing thorough the dynamometer.

IV Min X

This is the speed below which the inlet valve will be set
to IV Minimum Position

IV Max X

This is the speed at which the inlet valve will be set to IV


Maximum Position.

For speeds between IV Min X and IV Max X the inlet


valve will move linearly between IV Minimum and IV
Maximum positions.
IV Minimum Position

This is the minimum position the inlet valve will attain


when in automatic mode and should be set to the inlet
valve opening required for minimum load.

IV Maximum Position

This is the maximum position the inlet valve will attain


when in automatic mode and should be set to the inlet
valve opening required for maximum load

Inlet Valve Ctrl OP

The actual demand being sent to the inlet valve


controller. This valve is ranged 0 to 1 and equates to 0 to
100 % positional output to the valve. This field is useful
when setting up to confirm the correct operation of the
valve.

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.

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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.

3.8.23 The Cross-Coupling Effect of Control Mode Pairs


The operation of the PID control loops for the throttle and dynamometer are independent.
However, when both the dynamometer and throttle are under closed loop control the action of
one PID control loop will inevitably effect the controlled parameter of other PID control loop.
For example:

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

Consider a system running in the Torque Speed control mode. Increasing


the P coefficient of the throttle torque control loop causes instabilities in the
system; these instabilities may be improved by decreasing the D coefficient
of the dynamometer speed control loop.

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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:

To restore stability to a system it considered necessary to reduce the P


coefficient of the throttle control loop to less than 30% of the P coefficient of
the dynamometer control loop. Under these circumstances, the dynamometer
P coefficient should be reduced instead.

3.8.24 PID Tuning Summary

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

Figure 3-41 Cross coupled mode pairs table

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.

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Control Mode Pair


Position Speed
Position Torque
Speed Position
Speed - Torque
Torque Speed
Torque Power Law
MAP Speed
MAP Power Law

Throttle PID Coefficients


P
I
D
1.00
1.00
0.10
1.00
1.00
0.00
1.00
1.00
0.00
1.00
1.00
0.00
1.00
1.00
0.00
1.00
1.00
0.00

Dynamometer PID Coefficients


P
I
D
7.50
0.30
1.00
3.00
0.50
0.30
1.00
1.00
0.00
3.00
0.60
0.50
1.50
0.50
0.30
3.00
0.60
0.30
1.50
0.50
0.30

Figure 3-42 Recommended PID Starting Coefficients

3.9

Configure Channel Mapping


In Texcel control systems certain channels are essential to the control and maintenance of the
Texcel System. As these channels may be configured with different names, or in a different
order between systems, the controller has to be able to reference these critical channels. The
controller handles this by maintaining a Channel Mapping section within the VME.INI
configuration file. This contains information mapping known system names recognised by the
controller to the Channel Names recognised by the user.
A Channel Mapping Editor is provided under the Instrumentation Access Level that
accesses all user configurable sections of this mapping information. This information will have
been configured at commissioning time by Froude and should only be changed if you add
additional equipment/instrumentation.

3.9.1 Using the Channel Mapping Editor


Warning

Adjusting Channel Mapping whilst running the engine is not recommended


and may result in incorrect operation of the system. It is therefore
recommended that the test bed be shut down before using the Channel
Mapping Editor

When Edit Channel Mapping is selected from the System Configuration menu, the
following dialog box is displayed:

Figure 3-43 Channel mapping editor

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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).

3.9.2 Example Selecting a Digital Output to be Controlled by the Test Sequence.


1.

Select Edit Channel Mapping from the System Configuration menu.

2.

Click on the Digital Output button.

3.

Click on the Mapping Channel field.

4.

Find Sequencer 1 in the drop down list.

5.

Double-click on Sequencer 1.

6.

Click on the Channel Name field.

7.

Select the required Digital Output.

8.

Click the Ok button.

9.

Click the X button to close the Channel Mapping Editor.

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.

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CONFIGURATION OF ANCILLARY DEVICES

4 CONFIGURATION OF ANCILLARY DEVICES


Ancillary devices are normally external devices used to take various measurements In-Cell.
Each device is normally interfaced to the Texcel controller using industry standard
communications media (for example, serial RS232C). Control of ancillary devices is normally
possible via status pages on the main instrumentation display, using the F3 Manual Log
With Ancillaries button or under automatic test control.

4.1

AVL Fuel Weigher


The AVL Fuel Weigher is interfaced to the Texcel system using an RS232C serial interface.
The connection point of the serial cable from the fuel weigher is normally marked on the
contract block schematics. The serial port used for communication with the fuel weigher is
defined in the device.ini file, which is located in the \data\Config\ directory.
Note:

the operational aspects including calibration of the AVL Fuel weigher are covered in
IM1346 Texcel Software Operator's Guide.

4.1.1 AVL Fuel Weigher Set-up


4.1.1.1 AVL 733 / 733S DIP switch settings;
S1 OFF
S2 - ON
S3 OFF
S4 - OFF
S5 OFF
S6 OFF
S7 - ON
S8 - OFF

; 733 Protocol with checksum


; 9600 baud
; add checksum
; not used
; calibration on AVL manual keyswitch

4.1.1.2 AVL730 DIP Switch Settings


S1-1 - OFF
S1-2 - ON
S1-3 - ON
S1-4 - ON
S1-5 ON
S1-6 - OFF
S1-7 - OFF
S1-8 - OFF
S2 2
S3 - A and B fitted

; 9600 baud

; add checksum

; V24 RS232C
; short out hardware handshake (i.e. 3 line interface)

4.1.1.3 Serial Line Connection


AVL733 J9 Pin
1
2
3
4

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

Copyright Froude Hofmann

CONFIGURATION OF ANCILLARY DEVICES

IM 1347/1 ISSUE 5

4.1.1.4 Diagnostic Indicators on the AVL 733


LED#
1
2
3
4
5
6
7

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

4.1.2 Channel Configuration


In supervisor level, select the System_ConfigurationEdit_Channel_Mapping editor ;

Figure 4-1 Fuel Weigher Channel Mapping

Confirm the following channels are mapped;


Mapping Channel
FuelWeight
FuelMassFlowRate
FuelCurrentWeight
FuelFillingState

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

4.1.3 Suggested Calculation Channels Derived from Fuel Channels


The following calculation channels may be entered to complement fuel measurement readings.
(Note that these calculations should be have scan rates set to a maximum of 1 second to
prevent skew in log data).
Engine_Capacity = PI * ((Bore / 10) ** 2) * (Stroke / 10) * NoOfCylinders
[Units = cc]

June 2009

BMEP

= 4 * PI * Torque / (Engine_Capacity / 1000)


[Units = kPa]

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]

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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).

AVL Smoke Meter


Note:

4.3

CONFIGURATION OF ANCILLARY DEVICES

the operational aspects including calibration of the AVL Smoke Meter are covered in
IM1346 Texcel Software Operator's Guide.

FG100 Fuel Meter


This device is used to derive the fuel consumption of the engine. The device is controlled using
several digital input and output signals on the sixteen-bit board (SBB). These signals are
normally pre-configured on the Texcel Controller unit when shipped. The FG100 consists of a
fuel measuring tube assembly mounted In-Cell and a 3U panel unit normally mounted in the
instrumentation rack in the operators area.
The measuring principle consists of pre-selecting a mass of fuel on the FG100 control panel or
under remote control from the Texcel system. When a measurement is requested the system
speed signal is monitored until the mass of fuel selected is consumed from the fuel meter. The
total revolutions from the speed signal and the total measurement time are recorded and the
equivalent consumption rate is returned in the Fuel Flow Rate instrumentation channel for
display and log. The fuel meter may be triggered for measurement manually or via and
automatic test stage.
The Digital I/O channels required are fixed and listed on the contract signal allocation block
drawings. The System ConfigurationChannel Mapping page should be used to map the
digital I/O channels to the software driver for the following signals
Digital Outputs
Fg100RemoteSelect
Fg100RemoteMeasure
Fg100RemoteCancel
Fg100RemoteAutoRange
Fg100RemoteRangeSelect1
Fg100RemoteRangeSelect2
Fg100RemoteRangeSelect3
Fg100EnableDigInBuffer
Digital Inputs
Fg100Measuring
Fg100HighFuelAlarm
Fg100LowFuelAlarm
Fg100AutoRangeConfirm
Fg100CancelPulse
Fg100RangeConfirm1
Fg100RangeConfirm2
Fg100RangeConfirm3
Fg100RevCountEnable
Fg100DigInBufferOk

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

Copyright Froude Hofmann

CONFIGURATION OF ANCILLARY DEVICES

Note:

4.4

IM 1347/1 ISSUE 5

It is recommended to run the FG100 in auto-range particularly under automatic test


sequence control as measurements triggered with a large weight selection may result
in excessive measuring periods possibly resulting a timeout error message and test
sequence hold.

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.

4.4.1 System Interface


The AVL735 Fuel Mass Flow Meter and AVL753 Fuel Temperature Controller are interfaced to the
control system as shown below.

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

E/Stop shutdown chain

AVL 753
Fuel Temperature
Controller

Texcel Based
Drivers (x2)

Texcel
Real-Time Processor (RTP)
COM 2

COM 2

Fuel & Water Services Available Interlock

Figure 4-2 AVL Fuel Unit Connections

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CONFIGURATION OF ANCILLARY DEVICES

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.

Copyright Froude Hofmann

CONFIGURATION OF ANCILLARY DEVICES

IM 1347/1 ISSUE 5

4.4.2 AVL Fuel Diagnostic Display


This display window is called from either of the AVL Fuel displays by pressing the Diagnostics
button. The parameters in this page show detailed feedback from each of the AVL fuel
devices. Most of the parameters are the raw inputs represented normally with the textual
status displays or error/warning messages in the main AVL device windows. Note that the
update rate of all signals is approximately 2 Hz. The intended use of this diagnostic display is
therefore as a secondary backup tool to diagnose any regularly reoccurring faults. In addition,
Maintenance mode can also be used to fault find.

Figure 4-3 AVL Fuel Unit Diagnostics Display

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.

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A description of each of the listed parameters is given below;


Parameter Name

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.

AVL735 Fuel Pump


Current

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.

AVL735 Fuel Pump


Pressure

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 pump is and option that is not normally fitted

AVL735 Fill Valve 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.

AVL735 Tank Overflow

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.

AVL735 Ext Vent


Request IP

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.

Disable 753 Vent OP

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).

AVL753 Fuel Flow

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

Copyright Froude Hofmann

CONFIGURATION OF ANCILLARY DEVICES

IM 1347/1 ISSUE 5

AVL753 Hybrid Media Ok

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

AVL753 External E Stop

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

AVL753 Coolant Pump

This pump is normally on whilst conditioning (measurement) mode is


active

AVL753 Coolant Flow

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.

4.4.3 Maintenance Operations


Each of the control dialogs for the AVL753 and the AVL 735 units has a maintenance button,
which is used to access the configuration applications for each device. When the maintenance
mode is selected, the AVL configuration application for the relevant fuel unit is started and both
devices are available for control, please refer to the AVL 735 Operation Manual section 2.5.3.
Once the AVL program displays on-screen each AVL device can be selected in turn and
monitored. If the device is placed into Remote mode the Texcel system will revert to passive
monitoring and will relinquish control to the AVL Program running on the PC.
Note when the AVL PC Program has Remote control of either device the Texcel system may
not be taking fuel readings. If a test is in progress on the Texcel system, fuel readings
may not be available for logging, display or alarm triggering.
The AVL PC Programmes can be used to control and diagnose each unit in the fuel system.
Certain operations such as calibration or accuracy checks may require between 1 and 8 hours
during which fuel flow must be maintained. It is possible to calibrate with the engine running
under stable test conditions (for example, during an prolonged endurance cycle) but fuel
measurements may not be possible during this period.
When maintenance procedures are completed using the AVL PC program, the Remote mode
must be cleared by pressing the Monitor button for both AVL devices to release control back to
the Texcel system. In the Texcel display options AncillariesAVL 735 Fuel Mass Flow Meter
and AncillariesAVL 753 Fuel Temperature Controller the User Status field indicates User =
AVL PC whilst the AVL PC Program has Remote control of the AVL devices.

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CONFIGURATION OF ANCILLARY DEVICES

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

in cm/s at sea level at latitude p.


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).

4.4.4 Supporting Documentation


The following documents should be referred to when installing and using the AVL fuel system.
The operation manuals for the AVL735 Fuel Mass Flow Meter, AVL753 Fuel Temperature
Conditioning and AVL PC Application program are supplied as paper manuals. These manuals
and several other supporting documents are also supplied on CD-ROM, (AVL Product Number
PA0610).

98

Manual Description

Electronic Document Filename

AVL753C Operating Instructions

AT1242E_02_Fuel_Temperature_Control.pdf

AVL735 Operating Instructions

AT0803E_05_Fuel_Mass_Flow_Meter.pdf

AVL 735 / 753 PC Software

AT1416E_01_PC_Software_735_753C.pdf

Copyright Froude Hofmann

CONFIGURATION OF ANCILLARY DEVICES

4.5

IM 1347/1 ISSUE 5

ASAM MCD 3MC Interface


This section deals with the installation and configuration of the optional ASAM MCD 3MC
interface application. This application enables Texcel control systems to communicate with
ECU calibration tools, which support the ASAM MCD 3MC (ASAP3) interface standard.
The ASAM MCD 3MC interface standard enables test bed control systems to control and
acquire data from a variety of ECU calibration tools and will show a common user interface and
operation irrespective of the manufacturer of the calibration tool.
The Texcel UIP is connected to the calibration tool PC via a serial cable for the interface and a
network cable to enable the Texcel UIP to read the ECU calibration and configuration files
which are stored on the calibration tool disk drive. The disk drive containing the configuration
files is then mapped onto the Texcel UIP.
The following sections deal with installation and configuration of the Texcel ASAM MCD 3MC
interface software, for detailed information on operation of the interface application please refer
to the online help for the interface.

4.5.1 Software Installation


The ASAM MCD 3MC interface application is supplied on all Texcel systems in the \Apps
directory on the UIP. A password required for installation is provided when the option has been
purchased or the software is being installed by a Froude Hofmann commissioning engineer.
To install the software choose the ASAM MCD 3MC option from the main installation dialog
screen and follow the onscreen instructions to install the software from the Texcel CD.

4.5.2 Calibration Tool Drive Mapping


In order for the Texcel UIP to have access to the ASAP2 format configuration files on the
calibration tool it is necessary to connect the calibration tool PC to a network which can be
accessed from the Texcel User Interface Processor. This is usually achieved by connecting the
cal tool PC and the Texcel UIP together via a separate crossed network cable or by installing
the calibration tool PC onto the Texcel network via a network hub.
It is also possible to run the calibration tool and ASAM MCD 3MC interface software on the
same PC in which case a network connection is not required.
Once the network has been connected and correctly configured the disk drive containing the
calibration tool configuration files must be mapped onto an unused drive letter on the Texcel
UIP, which is done as follows;
Using Windows Explorer on the Texcel UIP select the Tools -> Map Network Drive option
and select an unused drive letter. In the Path: dropdown box enter the name (or IP address) of
the calibration tool PC followed by the name of the drive to be used in the following form;
\\Name of Calibration tool PC\Name of the drive holding the configuration files $
e.g.
If the calibration tool PC is called TheCalToolPC and the configuration files reside on the C
drive then the entry in the path field will be
\\TheCalToolPC\C$

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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.

4.5.3 Communication Configuration.


The actual interface between the calibration tool PC and the Texcel UIP is a serial
communications link, which has to be connected and configured before the interface can be
used. Using the serial interface cable supplied connect a spare calibration tool PC serial port to
the designated serial port on the Texcel UIP.
Configure the calibration tool software to use the chosen port, details of how to configure the
communications will differ depending on the manufacturer of the calibration tool so please refer
to the manufacturers documentation for the specific calibration tool being used. At the Texcel
UIP select Ancillaries -> ASAM MCD 3MC Interface to start the interface application. In the
ASAM MCD 3MC interface application select Configure -> Communications and set the
coms port number to the number of the UIP serial port being used and the baud rate to 9600.
The baud rate can be increased if the particular calibration tool supports a faster baud rate, this
method is often used to increase the performance of the ASAM MCD 3MC interface, however
the official ASAM standard is 9600 baud.

4.5.4 Calibration Tool Timeout Settings.


Each command sent and received on the ASAM MCD 3MC interface has an associated timeout
and these timeouts will differ between different calibration tools from different manufacturers.
The supplied timeout file will work with ETAS INCA calibration tools using an ETK for ECU
communications but may require modification when used with calibration tools from other
manufacturers or ETAS tools using different ECU interfaces.
If timeout errors are seen when using the interface then the timeout for the particular command
being used should be increased until reliable communications are achieved. The timeouts
should not be set too large as this will result in long delays before error messages are
displayed should a communications error occur.
The timeouts are defined in \froude\apps\ASAM MCD\timeout.ini that is a text file and can be
edited with any text editor. The ASAM MCD 3MC interface software will have to be stopped and
restarted for any timeout changes to be implemented.

4.5.5 ASAM MCD 3MC interface Initial Startup


The ASAM MCD 3MC interface application is designed to restore its previous configuration on
startup that removes the necessity to configure the application each time it is used. On initial
start-up there is no previous configuration to restore so it is necessary to choose the path to the
configuration files (on the mapped drive as detailed above) and the configuration and data files
to be used.
Once chosen these settings are stored so this procedure is only required on the first start-up of
the application.
For details of the operation of the ASAM MCD 3MC interface software please refer to the
Texcel user manual IM1346 and the online help for the Textool application.

100

Copyright Froude Hofmann

CONFIGURATION OF ANCILLARY DEVICES

4.6

IM 1347/1 ISSUE 5

Electronic Throttle Control

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.

4.6.1 Configuration of the Electronic Throttle Control.

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.

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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.

Figure 4-4 Power Unit Throttle Control Parameters

Each of these four variables will require modification to match the respective feedback voltages from
the accelerator pedal position sensor,

User Data Variable Name

Set to this value

ThrotT1MinVolts

Pedal Sensor Track 1 Voltage at 0% Accelerator pedal position.

ThrotT1MaxVolts

Pedal Sensor Track 1 Voltage at 100% Accelerator pedal position.

ThrotT2MinVolts

Pedal Sensor Track 2 Voltage at 0% Accelerator pedal position.

ThrotT2MinVolts

Pedal Sensor Track 2 Voltage at 0% Accelerator pedal position.

4.6.3 Testing the Electronic Throttle Control

102

Configure the power unit variables for the pedal voltages required.

Copyright Froude Hofmann

CONFIGURATION OF ANCILLARY DEVICES

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.

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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

Instrumentation Package (User Interface Processor - PC)


Access Level
Operator

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).

Figure 5-1 Access level passwords

5.2

Texcel Controller (Real Time Processor RTP)


Note that access to the controller unit is via the Texcel Serial Diagnostic Link (HyperTerminal)
which is normally available as an icon on the Windows Start menu or on the Desktop. This
facility is only required for specific maintenance and diagnostic tasks only (e.g. software
upgrade) and should not be used under normal running conditions.
User name
Guest
Root

Password
Froude
Texcel

Description
Used for diagnostic investigation only
Used for maintenance and diagnostics

Figure 5-2 RTP operating system logins

Note:

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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.

Figure 6-1 Printer setup dialog

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.

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Figure 6-2 Print dialog

6.1.1 Installing a Printer


This requires the PC to be logged in at administrator level.

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.

Figure 6-3 Windows Printer control panel dialog

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.

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Figure 6-4 connecting to network printer

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.

6.1.2 Uninstalling a Printer


If a printer driver is removed from the PC, particularly if the printer was used previously within
the graphical instrumentation package, the following procedure should be used.

Login to the PC at administrator level.

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.

Select StartRun and enter Regedit, press Ok

Click the Select EditFind and search for KineticaRT.

Figure 6-5 registry search options

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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

Figure 6-6 Registry Editor

Click on the PrinterSetup directory if present, select EditDelete to remove it.

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.

Select RegistryExit when complete.

The Texcel graphical instrumentation package may be restarted.

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.

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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.

Figure 6-7 Example VME monitor display

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.

Figure 6-8 Example Probe display

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7 DATA MANAGEMENT
7.1

Data Storage on the Texcel


How and where the Texcel system stores test and configuration data is dependent on the type
of Texcel system.
The Texcel V8 system uses the UIP hard disk to store the configuration and logged data. As all
logged data is stored on the Texcel UIP regular maintenance must be performed to ensure the
Texcel UIP disk does not overflow the storage space available.
The Texcel V4 PLUS,V4 Advantage, V6, V10 and V12 systems use a hard disk located in the
RTP to store the configuration and logged data. This disk is mounted onto the UIP via the
network so the RTP disk looks like any other disk connected to the PC. This arrangement
allows easy backup of the test cell configuration and test data and allows other networked PCs
access to the test data.

7.1.1 The PC Program and Configuration Data Storage


The storage requirement on the PC (UIP) is reasonably limited. All programs and data required
for the Excel editors (Test Sequencer, Alarm Editor, Data Analysis and Comment Log Editor)
and the main graphical instrumentation package are stored in the directory \Froude. This
directory is arranged as follows;

Figure 7-1 Directory structure

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.

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Figure 7-2 Example directory listing

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

File Handler Option - Automatic Data Transfer


The File Handler utility is available which may optionally be installed to assist with the
management of configuration and test result data. When running, the File Handler utility can
be configured to regularly backup configuration and test result logged data files to the PC (UIP)
hard drive or possibly to a central host computer where the PC is interfaced to a customer
network.

7.2.1 File Handler Utility Installation


The File Handler utility is normally supplied on the installation media (usually CD-ROM),
along with the main Texcel application software. Use Windows NT Explorer to browse the
CD and double click on the Texcel File Handler Utility.EXE program to run it. Follow the onscreen instructions.

Figure 7-3 file handler installation

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Figure 7-4 File handler start-up options

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.

Figure 7-5 File handler confirmation dialog

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

File Handler Default Installation Settings


By default the File Handler application will run minimised on the Windows NT task-bar. The
default configuration will transfer configuration files from the Texcel UIP hard disk \Data to the
PC directory tree located in C:\Backup\Froude\Texcel Dynamic Data Export.
Every five minutes the changes in power units, alarm and sequence files are updated to the PC
(the original files on the Texcel UIP remain, copies are taken to the PC into separate subdirectories within the backup area.
The \Data\Results directory on the Texcel UIP hard drive is also checked for any newly
completed tests. These will be moved from the Texcel UIP hard drive to the PC (i.e. the
originals will be deleted). (A completed test is identified by the presence of test completion flag
file TestName.fin).

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7.2.3 File Handler Re-configuration


Windows NT Explorer should be used to create the destination backup tree with sub-directories
before re-configuring the File Handler application. The default configuration for example is
shown in the following figure.

Figure 7-6 File handler directory structure

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).

Figure 7-7 Main file Handler display

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.

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Figure 7-8 Configure power unit transfer

Figure 7-9 Configure Sequence transfer

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Figure 7-10 Configure alarm file transfer

Figure 7-11 Configure test results transfer

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.

7.2.4 File Handler Alternative Configuration Automatic Archive To Host


Where the PC (UIP) is networked to a host PC, (possibly with other test bed computers), the
File Handler application may be re-configured differently to update all configuration type files
(power units, alarms and sequences), to download from the host to the Texcel system.
This may be useful where all test beds share the same standard test configurations. Each
power unit, alarm file set and test sequence may be edited on the host computer (or on one of
the test bed computers then uploaded on completion). If the File Handler application is reconfigured and running on each test bed the configuration data may be made available by the
host via a networked drive in a common release area. Each time one of the centrally stored
test files is modified, the File Handler software will automatically download the modified file(s)
to the test bed. The modified file(s) are then applied when a new test is started.
For example, if the data tree shown in Figure 7-6 is created on the host server computer, each
test bed Texcel system runs the File Handler application with the Source Directory set to refer
to the host data files and the Destination Directory is set to the Texcel UIP hard drive.
For example, if the host network drive is mapped as H: and the Texcel UIP hard disk data
directory is T:, the power units could be maintained at the central host server and automatically
updated on the test bed Texcel by reconfiguring the File Handler as follows ;

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Figure 7-12 Example configuration for file transfer to host

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.

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8 GENERAL NOTES ON USE OF THE TEXCEL SYSTEM


This chapter lists various useful notes and tips on the use of the Texcel system.

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.

8.1.1 Saving Modifications When Using the Main Instrumentation Package


The main instrumentation package allows various levels of access and most data entry
methods change the run-time data in the active memory of the Texcel Controller (RTP). All
settings are saved in configuration files. To cause the system to write the modifications to
configuration files normally requires a secondary action to trigger the system to update the files
with the modifications in memory. This secondary action may be clicking on a Save button,
closing a configuration page or starting a test.
Example 1:
Entries made to the Test ControlIdentify Test box are saved when a test is started with Test
ControlStart a Manual/Automatic Test.
Example 2:
Adjustments to the throttle or dynamometer control mode and set-points using the Test
ControlDemand Control box are applied in memory to a running automatic test sequence by
pressing the Update Stage Buffer button. To subsequently commit the adjustments to the
automatic test sequence file press the Save To Sequence File button.
Example 3:
Modification to the current set-points of the External Device Demands (such as water or oil
controller set-points) are written to file by pressing the Save button.
Example 4:
Changes made using the Test ConfigurationPower Law Editor are committed to file when
the configuration window is closed.
Example 5:
In the Test ConfigurationConfigure Rolling Store, modification to the channel list or logging
frequency is applied when the Ok button is pressed. (Note that closing the window without
pressing Ok will discard any modifications).
Example 6:
Modifications in the Test ConfigurationConfigure Periodic Log Set window are saved to file
when the Ok button is pressed. (Note that the channel configurations stored on file are not
applied to the system until the file is referenced in an automatic test sequence or in the Test
ControlIdentify TestPeriodic Log Set entry and a manual or automatic test is started).

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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.

8.1.2 System Settings that are Not Saved


Some settings are not recorded to file and are therefore volatile they are lost when the
system is re-started or powered off. Such settings include;

118

Emergency shutdown chain reverts to the disabled state.

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
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Selecting Display Pages Automatically


The selection of instrumentation pages is normally achieved by clicking one of the page buttons
on the lower part of the display. The pages may also be driven automatically by including a
special channel into the instrumentation file.

8.2.1 Selecting a Page Using a Calculation


The example calculation below demonstrates the facility to control the instrumentation page
based on the state of an I/O channel. The calculation should be added for a special reserved
channel name Page_Selector, (adding a calculation is covered in Section 3.1.8).
The result of the calculation Page_Selector should be an integer value between 1 and 9 to
select a page or 0 the passive state allowing the user to select pages using the page keys or
buttons on the display. Note that if a positive integer value is returned continuously from the
calculation no other pages can be selected.
The calculation changes to instrumentation page 5 when the shutdown chain is reset in
preparation to run the system. If the shutdown chain drops due to the loss of a safety interlock
or alarm the instrumentation page 6 is selected.
The additional use of local variables in the calculation ensure that the calculation result is zero
for most of the time. When the Shutdown Status digital input channel changes state the
appropriate page number 5 or 6 is returned depending on the state of the digital input.
In this example, instrumentation page 5 may be configured with the channels appropriate to
engine starting such as Speed, Torque and critical temperatures and pressures, page 6 may
contain channels that are appropriate to diagnose the shutdown such as digital input nodes of
the shutdown chain.
R:25 Page_Selector
If( Shutdown_Status > 0 )
newPage
=5
Else
newPage
=6
Endif
If( newPage <> oldPage )
pageRequest = newPage
oldPage
= newPage
Else
pageRequest = 0
Endif
Return( pageRequest )

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8.2.2 Selecting a Page from an Automatic Test Using a General Controller


The formula to determine the required instrumentation page may be more sophisticated than
that given in the previous section. The following example drives the page to be selected from
the current level of an analogue output channel.
All analogue output channels return an engineering value in the range 0 to 1. The following
example applies the factor 10 to give the full range of pages available. Analogue outputs are
normally driven from PID controllers. An external controller could therefore be configured to
drive the analogue output in question (if the analogue output is not physically connected to
external equipment, the channel does not require calibration when used in this way).
In the external controller configuration, the output channel is nominated and feedback channels
are not specified. The P term should be set to 0.1 allowing a page number to be specified as
the set-point demand to the controller. Since the set-points for external controllers may be
specified in automatic test sequence stages, pages may be selected by applying a page
number as the set-point to the external controller that drives the analogue output referred to in
the calculation. An auto-start stage could automatically select the instrumentation page
appropriate for engine starting for example.
R: 25 Page_Selector
newPage = SBB_Analog_OP_4 * 10
If( newPage <> oldPage )
pageRequest = newPage
oldPage
= newPage
Else
pageRequest = 0
Endif
Return( pageRequest )

8.3

EURO 3 & EURO 4 Test sequences

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.

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8.3.1 Configuration for Using the EURO tests.


The Euro tests are factory configured when the Texcel is supplied as part of an AC dynamometer
control system however it is possible to use the ESC and ELR test sequences with an absorb only
dynamometer.
If the ESC, ELR and ESC.SEQ files do not appear in the Sequence File Selection list on the Test
Identify dialog box then the Texcel has not been supplied preconfigured to run EURO tests. When
the tests have not been preconfigured it is necessary to contact Froude Hofmann Technical support to
obtain the required test sequence files and to set up the following configurations in order to use the
tests.
The configuration changes are shown below, in case of difficulty in setting up these configurations or
if the user is not conversant with changing the Texcel controller configuration it is strongly
recommended they contact Froude Hofmann Technical support.
Before making any changes to the VME.INI configuration file a backup copy must be made.
After making a backup copy of the VME.INI configuration file. Open the VME.INI file for the controller
and make the following changes.
Note: In the following channels the User names and channel numbers don't matter and will be
whatever channel number corresponds to the addresses used, however the SOURCE NAMES AND
THE ADDRESSES must be EXACTLY as shown. Where channels are being added to the VME.INI
file then the number of channels entry at the start of the file must be increased to match the channel
number of the last channel in the file.
The items shown in italics are details of the changes and do not need to be part of the configuration
file.
These are the entries added to the [STATUSMESSAGE] definition.
ETCRefSpeed
ETCIdleSpeed
ETCRefFileName

= 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

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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

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[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

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[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.

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Configuration Details for Sequencer Special Functions

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.

8.4.1 Wait for operator checks.


As well as the conditional end of stage features the test sequence editor can also be configured to
pause at the end of a test in order for the operator to perform any subjective type tests, which may be
required on the engine (such as visual inspection for oil leaks etc).
In order to do these checks there must be the following entries in the vme.ini file, these entries should
be added to the bottom of the existing vme.ini file and given sequential channel numbers following on
from the last existing channel number.
[ChannelXXX]
ChannelType = DigitalOutput
(change this type for channel type required)
SourceName = OperatorChecks
(name must be as shown)
UserName = Do Operator Checks
(does not matter, configure for customers requirements)
Address = SYSV:00:DO:XX
(Use next available SysVar number)
ConnectionPointID = Displays operator checks page
[ChannelYYY]
ChannelType = DigitalInput
(change this type for channel type required)
SourceName = ChecksComplete
(name must be as shown)
UserName = Checks Completed
(does not matter, configure for customers requirements)
Address = SYSV:00:DO:XX
(Use next available SysVar number)
ConnectionPointID = Dismisses operator checks page
The test sequencer will pause until the operator presses a Checks Complete button, this button can
be a physical button mounted somewhere in the test cell or a software driven button on the operator
user interface pages, if a physical button is used then change the channel type of the Checks
Complete channel to DigitalInput and set the address field to use the address of the digital input the
button is connected to.
A dialog is presented to the user to enable the entry of any comments, which may be required, and
the user can set the test status to Passed or Failed.
The difference between this operation and the use of the digital input end of stage condition to end a
test stage is that this option is not time limited, the test will pause until the Checks Completed input is
true.

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GENERAL NOTES ON USE OF THE TEXCEL SYSTEM

8.4.2 External Log Trigger


The one log per second set-point logging can be triggered from an external source, this allows the
start of logging to be synchronised with an external event.
In order to do this there must be the following entry in the vme.ini file, this entry should be added to
the bottom of the existing vme.ini file and given a sequential channel number following on from the
last existing channel number.
[ChannelXXX]
ChannelType = DigitalOutput
SourceName = LogEnable
UserName = Gate 1 Sec Log
Address = PMF:00:DO:08
ConnectionPointID = PMF +C27/-A/C31

(change to channel type required)


(change to customer requirements)
(change for input used)
(change for input used)

8.4.3 External Log Synchronisation


The one log per second setpoint log timing can be synchronised with an external source to ensure
that the external device logging and the Texcel logging is happening at the same point. This will often
remove the requirement to time align data when some of the data is from an external source.
In order to do this there must be the following entry in the vme.ini file, this entry should be added to
the bottom of the existing vme.ini file and given a sequential channel number following on from the
last existing channel number.
[ChannelXXX]
ChannelType = DigitalOutput
SourceName = LogSync
UserName = Sync 1 Sec Log
Address = PMF:00:DO:08
ConnectionPointID = PMF +C27/-A/C31

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(change to channel type required)


(change to customer requirements)
(change for input used)
(change for input used)

Copyright Froude Hofmann

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

Dynamometer & Throttle Controller, contains the minimum pulse, analogue


and digital input and output signals to drive a dynamometer, throttle and
engine enabling and monitoring the minimum system.

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

High resolution counter, this board provides six high-resolution pulse /


encoder channel inputs.

Load Cell

Transducer mounted to a dynamometer to measure the amount of torque


applied.

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

peripheral component interconnect, an I/O bus found in most modern PCs.


All processor, data acquisition and control boards fitted to the Texcel V4
PLUS, V4 Advantage and V10 systems conform to this standard.

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.

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9.2

GLOSSARY

PSC

PCI signal-conditioning card, this card is used in V4 PLUS, V4 Advantage


and V10 systems. Provides 16 analogue input channels, input type selection
is software controlled.

Rotary Encoder

Optical device for measuring the revolution of a shaft normally to derive


speed for control feedback.

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

Signal Conditioning Card provides conditioning for up to sixteen separate


analogue input channels and may be separately configured to handle
temperatures, pressures or other types of linear or non-linear voltage or
current input.

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.

User Interface Related Terms


Arrow

A box containing a downward pointing arrow.

Button

A control that is activated by clicking

Click

Pointing at a control and pressing the left mouse button

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

Pointing at a control and pressing the left mouse button twice

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.

Copyright Froude Hofmann

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

A button on the PC keyboard

List Box

A multi-line text box, with a scroll bar, from which an item is selected by
clicking.

Push-button

A push button switch on the manual control panel.

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.

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SUPPORT DATA

10 SUPPORT DATA
Information in this section is for reference purposes only.

10.1 Temperature Conversion Table C F

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10.1.1 PT100 Platinum Resistance Tables

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10.1.2 K Type Thermocouple Tables

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SUPPORT DATA

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SUPPORT DATA

10.1.3 J Type Thermocouple Tables

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SUPPORT DATA

IM 1347/1 ISSUE 5

PC Serial Port Pin Connections


9 Way D Type

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

10.2 General Texcel Controller Data


This section contains details of the different Texcel control system hardware.

10.2.1 Environment (Temperature / Humidity)


Controller and Desk Top Module

0 to 35C, 0 to 90% non-condensing

In-Cell Box and Transducer Box

0 to 50C, 0 to 90% non-condensing

10.2.2 Electrical Supply

Controller

250VA @ 110 or 230 V 10%, (50 to 60 Hz)

PC display

200W @ 110 or 230V 10%, (50 to 60 Hz)

In-Cell Box (HO/AC dynamometer)

500VA @ 110V or 230V 10%, (50 to 60 Hz)

In-Cell Box (EC dynamometer)

1.7kVA @ 230V 10%, (50 to 60 Hz)

10.2.3 SCC Board Specification


Board Name

Signal Conditioning Card (SCC).

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

2 or 3 wire type PT100, 100 at 0C.

Strain Gauge
(Pressure) Inputs

Differential, 100mV to 1V full scale, 5V or 10V excitation (100mA max).

Direct Voltage Input

100mV, 1V and 10V.

Non-Linear Inputs

Up to 40 break-points (interpolated) per channel.

Cold Junction

Using Channel 0 with built-in external PRT.

Isolation

1M from system ground.

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SUPPORT DATA

Input Filter

8Hz.

Diagnostic

T/C open circuit detection (using software high alarm setting)

10.2.4 PSC Board Specification


Board Name

PCI Signal conditioning board (PSC).

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

2 or 3 wire type PT100, 100 at 0C.

Strain Gauge
(Pressure) Inputs

Differential, 100mV to 1V full scale, +/- 10V excitation (100mA max).

Direct Voltage Input

100mV, 1V and 10V.

Non-Linear Inputs

Up to 40 break-points (interpolated) per channel.

Cold Junction

Using Channel 0 with built-in external PRT.

Isolation

1M from system ground.

Input Filter

10 Hz Low pass.

Diagnostic

T/C open circuit detection (using software high alarm setting)

10.2.5 ECC Board Specification


Board Name

Eight Channel Counter (ECC).

Number Of Channels
Per Board

8, each with four software programmable inputs.

Opto - Isolated Input

3V to 13V Peak, 100KHz max.

AC Type Input

100mV to 48V AC RMS. 100KHz max at 1V RMS min. (MUST be zero


crossing).

TTL Input

100KHz max

TTL Input (Schmidt


triggered)

100KHz max

Opto - Isolated Output


(All inputs)

Open Collector, 30KHz max. with 1K5 Ohm load to 15V dc. Mark / Space
ratio - 3:1.

TTL Output (AC &


Opto-isolated inputs)

Software Programmable to maximum frequency of input.

Diagnostic

Internally Generated Test Clock @ 7812Hz / 15625Hz / 31250Hz /


62500Hz.

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IM 1347/1 ISSUE 5

10.2.6 HRC Board Specification


Board Name

High Resolution Counter (HRC).

Number Of Channels
Per Board

6, software programmable inputs.

Opto - Isolated Input

3V to 13V Peak, 100KHz max.

AC Type Input

100mV to 48V AC RMS. 100KHz max at 1V RMS min. (MUST be zero


crossing).

TTL Input

100KHz max

Encoder Inputs

TTL Differential phase 12Hz to 250 KHz. 5V encoder supply @400 mA

Opto - Isolated Output


(All inputs)

Open Collector, 30KHz max. with 1K5 Ohm load to 15V dc. Mark / Space
ratio - 3:1.

10.2.7 SBB Board Specification


Board Name

Sixteen Bit Input Output Board (SBB).

Number Of Channels
Per Board

16 off Digital Inputs, 16 off Digital Outputs, 8 off Analogue Outputs, 2 off
Serial Communications Ports.

Digital Inputs

Opto Isolated, current Sinking, 5K6 Ohms Input Impedance

Logic High (Input On)

12V to 45V dc.

Logic Low (Input Off)

0V to 2V dc.

Digital Outputs

Normally Open Relay Contact. All outputs use Shared Common


connection. 48V dc at 1Amp max. each contact, 2Amps total for all
outputs.

Analogue Outputs

Link Configurable for 10V, 20mA, 16 bit resolution.

Serial Communication
Port

RS 232 using TxD, RxD, RTS and CTS only at 9600 baud.

10.2.8 PMF Board Specification


Board Name

PCI multi function board (PMF).

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

Logic High (Input On)

12V to 48V dc.

Logic Low (Input Off)

0V to 2V dc.

Digital Outputs

Normally Open Relay Contact. All outputs use Shared Common


connection. 48V dc at 1Amp max. Each contact, 2Amps total for all
outputs.

Analogue Outputs

Software Configurable for 10V, 20mA, 12 bit resolution.

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Encoder Inputs

TTL differential phase input range 12 Hz to 250 KHz.

Pulse input

100mV to 48 VAC, 100KHz max. Opto isolated from TTL circuitry

10.2.9 DX100 Specification


Board Name

DX100 Distributed I/0 Control Module

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

Optically Isolated, 4.7K Ohms Input Impedance, Input Voltage + 24V

Digital Outputs

Galvanically Isolated, Volt Free Contact. 24V DC at 1Amp max. each


contact.

Analogue Outputs

Either 10V (all channels) or 20mA (all channels), 16 bit resolution.

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

Cell Interface Details

Servo Circuits
Number of servos

Drive Current

100mA

Feed-back Potentiometer

1K.Ohm

Excitation Voltage

10V

EC Dynamometer Circuit
Type

Thyristor controlled 100HZ

Current

0 to 5 Amps or 10Amps From a supply voltage of 220 V A.C.


NOT MAINS ISOLATED

TX21 Throttle Actuator Driver


Type

Switch mode 25KHz (3Hz)

Current

7.5 Amps

Engine Control Relay Outputs


Number of relays

Type

Changeover contact

Rating

100mA @ 24V DC/AC

10.2.11

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SUPPORT DATA

10.2.12

IM 1347/1 ISSUE 5

Transducer Box Details

Number of channels

32 (or 16 if only 1 loom fitted) comprising 31 (15) sensor inputs plus 1


cold junction reference.
Note: The cold junction channel may be used for an additional sensor
input, if no thermocouple inputs are fitted to the Transducer Box.

Sensor Connection

Refer to drawing 2E320086A002 for details of sensor connection.


Note: that this will only be required for sensor additions, as the
transducer box is supplied pre-wired for all sensors originally specified
by the customer.

Pressure Sensor
Coupling

Quick release BSPT female (when sensor supplied by Froude


Hofmann).

Loom length

5,10,15 or 20 metres (standard, other lengths available on request)

10.2.13

Engine Services Box (Optional)

Environment

Temperature Range : 0-50 deg C


Humidity Range : 0 to 90% Non - Condensing
Enclosures Protected to IP55

Power Requirement

+12V or +24V from customers PSU or Battery Via direct connection of


the Positive to fuse FU0203 and the Negative to the common busbar,
refer to drawing E320114A002 for details.

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

Positive and Negative Connectors (additional connector for solenoid)


Fused via FU0203 at 100A.

Glowplugs

Positive and Negative Connectors Fused via FU0204 at 25A

Alternator

Large Positive Connector for direct connection to battery, Fused via


FU0205 at 25A Small Positive Connector for Charging indicator lamp,
Not Fused.

Ignition

Two sets of Positive and Negative Connectors Fused via FU0206 at


25A

Supply

Two sets of Positive and Negative Connectors for ancillary equipment.


Fused via FU0207 at 25A

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

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TEXCEL V12 SYSTEM INFORMATION

11 TEXCEL V12 SYSTEM INFORMATION


11.1 DX100 Module
The DX100 Distributed I/O Control Module is used to provide distributed I/O and control for
use within the Froude Hofmann range of dynamometer systems. It consists of two parts, the
Terminator module and the Controller module. Several modules can be used together to
provide the control and signal conditioning needed by the system.
A high speed CAN communication interface is used to communicate between the modules
and other system components (PCs, servo amps, transducers).
Before the module can be used an application program has to be downloaded to the internal
flash memory. Froude Hofmann performs this procedure during system configuration.

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

11.1.2 Replacing a DX100 Controller Module


If the DX100 Controller modules needs replacing follow the procedure described below.

144

1.

Remove the 24V power supply from the Controller module.

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.

Replace the 24V power supply to the Controller module.

6.

Reboot the RTP system to force the configuration file (.mce) to automatically be
downloaded to the DX100 module.

7.

Power down and then power up the DX100 module.

Copyright Froude Hofmann

TEXCEL V12 SYSTEM INFORMATION

IM 1347/1 ISSUE 5

11.1.3 Upgrading the .mce Configuration file


If the DX100 Controller Configuration file needs upgrading follow the procedure described
below.
1.

Install the new .mce file onto the RTP system.

2.

Reboot the RTP system to force the configuration file ( .mce ) to be automatically
downloaded to the DX100 module.

3.

Power down and then power up the DX100 module.

11.2 CAN Communications


11.2.1 Checking the CAN Communications
The status of any Device on the CAN Network can be checked by monitoring certain pseudo
CAN digital inputs as shown below.

CAN Channel

Status - Energised

Status - De-energised

MDC Comms Ok

MDC communicating

MDC comms failure

Throttle Amp Comm Ok

Throttle Amp communicating

Throttle Amp comms failure

DX100 01 comms Ok

DX100 01 communicating

DX100 01 comms failure

DX100 03 comms Ok

DX100 03 communicating

DX100 03 comms failure

Comms to IO Ok

Beckhoff I/O communicating

Beckhoff I/O comms failure

If any Device fails to communicate across the CAN Network checks the following:

June 2009

The CAN cable is properly connected.


The CAN cable does not run near to any power cables.
The CAN network is correctly terminated at the last DX100 module and the throttle
amplifier.
The Manual Desktop Controller has been flashed ( look for label ).
The DX100 modules have been flashed.
The Elmo Dyno Controller has been flashed ( look for label ).

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11.3 CAN Pressure Transducers


Each CAN pressure transducer has to have a unique Node ID number. This allows
identification of an individual transducer on a CAN network containing several transducers.
Each transducer has to be programmed with the correct Node ID number and Baud Rate
before it can be used. When this procedure has been performed during system configuration
a label will be attached to the transduced identifying the Node ID number.
The table below shows the relationship between the DX100 channel address and its
corresponding Node ID number. Where XX represents the DX100 module number.

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.

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Copyright Froude Hofmann