Barber-Colman DYNA 8000, DYNA 8200, DYNA 8400 Technical Manual

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TECHNICAL MANUAL

FOR

DYNA 8000, 8200 & 8400

ELECTRONIC GOVERNOR

DYNA 8000

DYNA 8400

DYNA 8200

DYNA 8000-400 & DYNA 8400-400

F-23721-5

CONTENTS

SECTION DESCRIPTION PAGE

1 GENERAL INFORMATION........................... 3

2 SPECIFICATIONS.........................................3

3 FUNCTIONAL DESCRIPTION .....................5

4 INSTALLATION.............................................6

5 CALIBRATION OF DYN1-1065X.................. 9

6 CALIBRATION OF DYN1-1068X................ 11

7 TROUBLESHOOTING................................13

8 INSTALLATION DIMENSIONS................... 15

1. GENERAL INFORMATION

1.1 INTRODUCTION

The DYNA 8000, DYNA 8200 and DYNA 8400 governor system provides an engine governor for speed and power control of piston and gas turbine engines or steam and water turbines.

The actuator is a simple, proportional, electric solenoid having a sliding armature whose magnetic force is proportional to input coil current. The armature glides on anti-friction bearings and is balanced between the force of its return spring and the magnetic force, thus providing a hysteresis-free linear movement. The linear motion is converted to an output shaft rotation by a crank arm.

The hazardous duty DYNA 8000 and DYNA 8400 actuators provide units that are UL listed for Class I, Division 2, Group D, hazardous duty applications that are often encountered in the petroleum or chemical industries. The hazardous duty actuators can be used to provide an engine governor for speed and

power control of piston and gas turbine engines.

1.2 TYPICAL APPLICATIONS

Typical applications are speed governing, remote throttle control, generator sets, power carts and pump set applications.

1.3 STANDARD FEATURES

• All electric

• All engine compatible

• Mounts in any position

• Engine mounted (actuator only)

• High reliability due to few moving parts

• Proportional actuator

• No hydraulic or oil lines

• No special maintenance

• Spring returns output shaft to minimum position on removal

of power or loss of magnetic pickup signal

• Precise repeatability

2.1.10 DYNA 8000 CONTROLLER

Output Current @ 12 VDC

Output Current @ 24 VDC

Weight

2.1.11 DYNA 8000 CONTROLLER INPUT SIGNAL FREQUENCY

Input Signal

Frequency in Hertz

Select controller for the correct input signal frequency range generated by the magnetic pickup at the maximum engine operated (RPM) speed.

2.1.12 AVAILABLE CONTROLLER MODELS

Controllers: Speed Input Signal Frequency

Nominal Quiescent Current 80 mA Maximum Amperes @ Stall 13 amps Nominal Quiescent Current 80 mA Maximum Amperes @ Stall 13 amps Kilograms 0.863 Pounds 1.9

Engine RPM x Number of Gear

Teeth on Flywheel

60 Seconds

• DYN1-10652-000-0-12/24 250 - 1200 Hz

• DYN1-10653-000-0-12/24 1200 - 2500 Hz

• DYN1-10654-000-0-12/24 2500 - 5000 Hz

• DYN1-10656-000-0-12/24 5000 - 9500 Hz

• DYN1-10682-000-0-12/24 250 - 1200 Hz

• DYN1-10683-000-0-12/24 1200 - 2500 Hz

• DYN1-10684-000-0-12/24 2500 - 5000 Hz

• DYN1-10686-000-0-12/24 5000 - 9500 Hz

2.2. DYNA 8000 & DYNA 8000 UL APPROVAL, HAZARDOUS DUTY, CLASS 1, DIVISION 2, GROUP D ACTUATOR SPECIFICATIONS

2.2.1 Operating Voltage: 12 VDC or 25 VDC ±20%

2. SPECIFICATIONS

2.1 CONTROLLER SPECIFICATIONS

2.1.1 Operating Voltage: 12 VDC or 24 VDC ±20%

2.1.2 Ambient Operating Temperature:

-40 to +180°F (-40 to +85°C).

2.1.3 Temperature Stability: Better than ±0.5% over a temperature range of -40 to +167°F (-40 to +75°C).

2.1.4 Steady State Speed Band: ±0.25%

2.1.5 Adjustments: Speed, Gain, Integral, and Droop.

2.1.6 Circuit Boards: Boards are covered with a heavy

conformal coating for moisture and vibration protection.

2.1.7 Connection: Terminal strip.

2.1.8 Mechanical Vibration: Withstands the following vibra-

tion without failure of degraded performance: 0.06 inch double amplitude at 5 to 18 Hz; 1 G at 18 to 30 Hz; 0.02 inch double amplitude at 30 to 48 Hz; 2.5 G's at 48 to 70 Hz.

2.1.9 The same DYN1-1065X or DYN1-1068X Series can be used on a DYNA 8000, DYNA 8200 or DYNA 8400 actuator. The DYN1-1068X governor control box provides a wider range of adjustment than the DYN1-1065X. The DYN1-1068X can be used where maximum performance is desired or for some engines which are possibly more difficult to control.

2.2.2 Ambient Operating Temperature:

-65 to +255°F (-55 to +125°C).

2.2.3 Sealed Unit: Oil, water and dust tight.

2.2.4 Connection: Terminal strip or "MS" Connector.

2.2.5 Mechanical Vibration: 5 to 500 Hz, Curve F, per

MIL-STD. 810D, Method 514-2.

2.2.6 DYNA 8000 ACTUATORS

Work

Torque

Output Weight

Current @ 12 VDC

Current @ 24 VDC

Nominal Response Time for 63% of Stroke

(Seconds)

Joules 1.2 Foot-Pounds 0.9 Newton-Meters 1.4 Pound-Foot 1.0 Rotary 35° Kilograms 5 Pounds 11.0 Maximum Amperes @ Stall 12.5 Nominal Steady State Amperes 3.5 Maximum Amperes @ Stall 9.5 Nominal Steady State Amperes 1.5

0.030

2.2.7 AVAILABLE DYNA 8000 ACTUATOR MODELS WITH CLOCKWISE OUTPUT SHAFT ROTATION (Standard Mounted Units)

• DYNC-11020-000-0-12 Standard Clockwise

DYNC-11020-000-0-24 Output Shaft Rotation

2.2.11 AVAILABLE DYNA 8000 HAZARDOUS DUTY ACTUATOR MODELS WITH CLOCKWISE OUTPUT SHAFT ROTATION (Standard Mounted Units)

• DYNC-11020-400-0-12 Standard Clockwise

DYNC-11020-400-0-24 Output Shaft Rotation

• DYNC-11021-000-0-12 Actuator Head Positioned 180°

DYNC-11021-000-0-24 from Standard DYNC-11020

• DYNC-11022-000-0-12 Actuator Head Positioned 90°

DYNC-11022-000-0-24 CCW from Standard DYNC-11020

• DYNC-11023-000-0-12 Actuator Head Positioned 90°

DYNC-11023-000-0-24 CW from Standard DYNC-11020

2.2.8 AVAILABLE DYNA 8000 ACTUATOR MODELS WITH CLOCKWISE OUTPUT SHAFT ROTATION (Side Mounted Units)

• DYNC-11020-300-0-12 Standard Clockwise

DYNC-11020-300-0-24 Output Shaft Rotation

• DYNC-11021-300-0-12 Actuator Head Positioned 180°

DYNC-11021-300-0-24 from Standard DYNC-11020

• DYNC-11022-300-0-12 Actuator Head Positioned 90°

DYNC-11022-300-0-24 CCW from Standard DYNC-11020

• DYNC-11023-300-0-12 Actuator Head Positioned 90°

DYNC-11023-300-0-24 CW from Standard DYNC-11020

2.2.9 AVAILABLE DYNA 8000 ACTUATOR MODELS WITH COUNTERCLOCKWISE OUTPUT SHAFT ROTATION (Standard Mounted Units)

• DYNC-11024-000-0-12 Standard Clockwise

DYNC-11024-000-0-24 Output Shaft Rotation

• DYNC-11025-000-0-12 Actuator Head Positioned 90°

DYNC-11025-000-0-24 CW from Standard DYNC-11024

• DYNC-11026-000-0-12 Actuator Head Positioned 180°

DYNC-11026-000-0-24 CCW from Standard DYNC-11024

• DYNC-11021-400-0-12 Actuator Head Positioned 180°

DYNC-11021-400-0-24 from Standard DYNC-11020

• DYNC-11022-400-0-12 Actuator Head Positioned 90°

DYNC-11022-400-0-24 CCW from Standard DYNC-11020

2.2.12 AVAILABLE DYNA 8000 HAZARDOUS DUTY ACTUATOR MODELS WITH COUNTERCLOCKWISE OUTPUT SHAFT ROTATION (Standard Mounted Units)

• DYNC-11024-400-0-12 Standard Clockwise

DYNC-11024-400-0-24 Output Shaft Rotation

• DYNC-11025-400-0-12 Actuator Head Positioned 90°

DYNC-11025-400-0-24 CW from Standard DYNC-11024

• DYNC-11026-400-0-12 Actuator Head Positioned 180°

DYNC-11026-400-0-24 CCW from Standard DYNC-11024

2.2.13 AVAILABLE DYNA 8000 HAZARDOUS DUTY ACTUATOR MODELS WITH CLOCKWISE OUTPUT SHAFT ROTATION (Side Mounted Units)

• DYNC-11020-401-0-12 Standard Clockwise

DYNC-11020-401-0-24 Output Shaft Rotation

• DYNC-11021-401-0-12 Actuator Head Positioned 180°

DYNC-11021-401-0-24 from Standard DYNC-11020

• DYNC-11022-401-0-12 Actuator Head Positioned 90°

DYNC-11022-401-0-24 CCW from Standard DYNC-11020

2.2.14 AVAILABLE DYNA 8000 HAZARDOUS DUTY ACTUATOR MODELS WITH COUNTERCLOCKWISE OUTPUT SHAFT ROTATION (Side Mounted Units)

• DYNC-11024-401-0-12 Standard Clockwise

DYNC-11024-401-0-24 Output Shaft Rotation

• DYNC-11028-000-0-12 Actuator Head Positioned 90°

DYNC-11028-000-0-24 CCW from Standard DYNC-11024

2.2.10 AVAILABLE DYNA 8000 ACTUATOR MODELS WITH COUNTERCLOCKWISE OUTPUT SHAFT ROTATION (Side Mounted Units)

• DYNC-11024-300-0-12 Standard Clockwise

DYNC-11024-300-0-24 Output Shaft Rotation

• DYNC-11025-300-0-12 Actuator Head Positioned 90°

DYNC-11025-300-0-24 CW from Standard DYNC-11024

• DYNC-11026-300-0-12 Actuator Head Positioned 180°

DYNC-11026-300-0-24 CCW from Standard DYNC-11024

• DYNC-11028-300-0-12 Actuator Head Positioned 90°

• DYNC-11028-300-0-24 CCW from Standard DYNC-11024

• DYNC-11025-401-0-12 Actuator Head Positioned 90°

DYNC-11025-401-0-24 CW from Standard DYNC-11024

• DYNC-11026-401-0-12 Actuator Head Positioned 180°

DYNC-11026-401-0-24 CCW from Standard DYNC-11024

2.3 DYNA 8200 ACTUATORS

2.3.1 Operating Voltage: 12 or 24 VDC ±20%.

2.3.2 Ambient Operating Temperature:

-65 to +255F (-55 to +125°C).

2.3.3 Sealed Unit: Oil, water and dust tight.

2.3.4 Connection: Terminal strip or "MS Connector.

2.3.5 Mechanical Vibration: 5 to 500 Hz, Curve F, per MIL-

STD. 810D, Method 514-2.

Work

Torque

Output Weight

Current@ 12 VDC

Current @ 24 VDC

Nominal Response Time for 63% of Stroke (Seconds)

Joules 2.85 Foot-Pounds 2.10 Newton-Meters 4.07 Pound-Foot 3.00 Rotary 45° Kilograms 8.4 Pounds 18.5 Maximum Amperes @ Stall 14.75 Nominal Steady State Amperes 4.5 Maximum Amperes @ Stall 14.0 Nominal Steady State Amperes 3.5

.138

2.3.6 AVAILABLE DYNA 8200 ACTUATOR MODELS WITH CLOCKWISE OUTPUT SHAFT ROTATION

• DYNC-12000-000-0-12 Standard Clockwise

DYNC-12000-000-0-24 Output Shaft Rotation

• DYNC-12001-000-0-12 Actuator Head Positioned 180°

DYNC-12001-000-0-24 from Standard DYNC-12000

• DYNC-12002-000-0-12 Actuator Head Positioned 90°

DYNC-12002-000-0-24 CCW from Standard DYNC-12000

• DYNC-12003-000-0-12 Actuator Head Positioned 90°

DYNC-12003-000-0-24 CW from Standard DYNC-12000

2.4 DYNA 8400 & DYNA 8400 UL APPROVAL, HAZARDOUS DUTY, CLASS 1, DIVISION 2, GROUP D ACTUATOR SPECIFICATIONS

2.4.1 Operating Voltage: 24 VDC ±20%.

2.4.2 Ambient Operating Temperature:

-65 to +255F (-55 to +125°C).

2.4.3 Sealed Unit: Oil, water and dust tight.

2.4.4 Connection: Terminal strip or "MS Connector.

2.4.5 Mechanical Vibration: 5 to 500 Hz, Curve F, per MIL-

STD. 810D, Method 514-2.

2.4.6 DYNA 8400 ACTUATORS

Work

Torque

Output Weight

Current @ 24 VDC Nominal Response Time for 63% of Stroke

(Seconds)

Joules 5.8 Foot-Pounds 4.3 Newton-Meters 7.3 Pound-Foot 5.4 Rotary 45° Kilograms 12.2 Pounds 27 Maximum Amperes @ Stall 13 Nominal Steady State Amperes 2.0

0.104

2.4.7 AVAILABLE DYNA 8400 ACTUATOR MODELS WITH TERMINAL STRIP CONNECTION

• DYNC-14800-000-0-24 Through Output Shaft Making

Available CW and CCW Output

2.4.8 AVAILABLE DYNA 8400 ACTUATOR MODELS WITH 2-PIN MS SCREW ON CONNECTOR

• DYNC-14801-000-0-24 Through Output Shaft Making

Available CW and CCW Output

2.4.9 AVAILABLE DYNA 8400 HAZARDOUS DUTY ACTUATOR WITH TERMINAL STRIP CONNECTION INSIDE CAST IRON JUNCTION BOX

• DYNC-14800-400-0-24 Through Output Shaft Making

Available CW and CCW Output

3. FUNCTIONAL DESCRIPTION

3.1 ACTUATOR

The actuator consists of an electro-magnet with an iron armature rolling on the center shaft bearings. The actuator is provided with a return spring which balances the magnetic force of the armature. When DC current flows in the coil, the magnetic force tends to move the armature in the stator and this linear motion is transformed into rotary motion through a crank arm that forms part of the output shaft.

3.2 CONTROLLER

The electronic controller is the information processing unit of the governor assembly. It contains electronic components which process the input signal from the magnetic pickup and control the engine to the desired speed/RPM set into the controller. Electronic adjustments are available on the controller for field adjusting the unit as necessary.

3.3 DC POWER SOURCE

The governor system receives its power from a battery or an AC to DC power supply supplying 12 or 24 VDC ±20% to match the governor voltage. The average operating current consumption is 2.5 to 3.5 amperes and the highest consumption is 14.75 amperes during engine start-up or during a large load change. The power source must be rated above maximum stall current.

3.4 COMPONENT LOCATION

The actuator of the governor assembly is mounted on the engine next to the fuel system. The magnetic pickup is normally mounted in the flywheel housing in such a way that it can count the teeth on the starter ring gear. The controller is off-mounted or installed in the engine control panel or cabinet.

3.5 ISOCHRONOUS OPERATION

3.7 REMOTE SPEED ADJUSTMENT

Isochronous operation is obtained by setting droop potentiometer fully counterclockwise. The DYNA governor is all electric, and it is normally operated in the isochronous mode; i.e., engine RPM is constant (±0.25%) under steady state load conditions, up to the engine's maximum capability, regardless of load on the engine.

Desired Engine RPM

Engine RPM

Isochronous

Operation Mode

Engine Load

100%

An optional remote speed selector (DYNS-10000) is available for adjusting engine RPM from up to 90 meters (300 ft.) from the engine. See the Electrical Wiring Schematic. The potentiometer can be connected for a narrow (fine) or wide speed range control.

4. INSTALLATION

4.1 PROCEDURE

4.1.1 Mount the actuator on a suitable rigid steel bracket or

plate.

NOTE

Mounting information and kits are usually available for a particular engine. Contact Sales Representative.

4.1.2 Set up the linkage and rod end bearings (see 4.2).

4.1.3 Install the speed sensor with SAE threads (magnetic

pickup)*.

*Magnetic pickups with metric threads are available.

Thread — M16 x 1.5 — 6 g. Tap Drill Size — 14.5 0 mm.

3.6 DROOP OPERATION

Droop operation is obtained by setting the droop potentiometer. Clockwise increases the droop. The amount of droop for a given setting depends on the magnetic pickup frequency and no load to full load actuator shaft rotation. A droop potentiometer setting of 10 o'clock will give about 4% droop, no load to full load when the pickup frequency is 4260 Hz and actuator shaft rotation is approximately 30 degrees from no load to full load. Lower pickup frequency or smaller shaft rotation results in less droop for the system.

No Load Engine RPM

Adjustable

Full Load Engine RPM

Engine RPM

4.1.3.1 Remove the inspection cover over the ring gear teeth. The teeth should be free of burrs, excessive grease or dirt.

4.1.3.2 The magnetic pickup should not be installed in inspection covers. Inspect the ring gear housing and pick a location where a 37/64" hole can be drilled such that the ring gear teeth will pass in front of the pickup pole face. After the 37/64" hole is drilled, use a 5/8-18 starting tap to cut threads for the magnetic pickup, then run a bottom tap through the hole.

NOTE

The tapped hole should be drilled as nearly perpendicular as possible over the center of the ring gear teeth.

4.1.3.3 Manually rotate the ring gear until a tooth face is directly in the center of the tapped hole. Gently turn the magnetic pickup clockwise into the hole until it bottoms on the tooth, and back off 1/4 turn. Tighten the jam nut firmly, maintaining the 1/4 turn position.

% of Engine Load

100%

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