Downloading - DSF Technologies
Contents
1. 15 DECEL RATE is the rate in MPU Hertz or RPM per second used to ramp to a new lower target speed 1000 STARTUP RATE is the rate in MPU Hertz or RPM per second at which the governor will ramp to the ae selected target speed when the engine is started Useful in limiting smoke at engine startup STARTUP LIMIT is the maximum actuator current output allowed when starting the engine Resolution is 0 1 so a value of 1000 means 100 Use to limit smoke at engine startup TORQUE LIMIT is the maximum actuator current output allowed during heavy generator load The resolution is 0 1 so a value of 1000 means 100 INTEGRAL LOW LIM is the duty cycle percentage where integration stops when the governor is trying to decrease engine speed It limits integral wind down Use with caution INTEGRAL HIGH LIM is the duty cycle percentage used to limit integral windup when the governor is trying to increase engine speed Use with caution DROOP is the percentage of droop desired adjustable in steps of 0 1 This means that a value of 99 represents 9 9 droop The Droop Calibration Procedure must be used to modify this parameter NO LOAD CAL is the calibrated actuator current needed to maintain the unloaded droop speed This parameter is set automatically during the Droop Calibration Procedure The resolution is 0 1 23 FULL LOAD CAL is the calibrated actuator current needed to maintain the selected target speed when the2. 1000 1800RPM 0 95 1895RPM NOTE This parameter can only be modified during the Droop Calibration Procedure See the Calibration Instructions chapter for more information Droop mode relies on knowing the actuator position The actuator s position corresponds to the amount of fuel being delivered to the engine The DPG 2201 001 controller senses electrical current flow through the actuator to determine its position This method of position sensing does not work with all actuators 3 22 No Load Calibration optional The No Load Calibration value is learned during the Droop Calibration Procedure and should not be set manually Once calibrated the no load calibration value indicates the percentage of electrical current relative to the measurable maximum that must flow through the actuator to run the engine at the no load droop speed The factory default value is zero so if droop mode is to be used this parameter must be calibrated The no load calibration value must be less than then the full load calibration value for proper droop operation If after performing the Droop Calibration Procedure the no load calibration value is greater than the full load calibration then the droop function can not be used Some actuators may have a current verses position curve that is incompatible with this controller s method of determining actuator position NOTE This parameter is only modified during the Droop Calibration Procedure See the Calibrat
3. 2000 or XP The display resolution needs to be set to SVGA 800x600 or higher The Universal PST program is not supported on Microsoft Windows 95 The program may work on Microsoft Windows ME Millennium Edition but this has not been tested 4 3 Acquiring Universal PST The Universal PST application is available to you at no additional cost for use with any COMM port equipped DPG Downloading software via the internet The files ReadMeFirst txt and Universal PST zip are available for download on the software download page at the www dynaproducts com website Requesting the Universal PST on CD ROM Contact the Barber Colman DYNA Products sales department to request a CD ROM copy of Universal PST Telephone 815 637 3000 44 Wiring the COMM Port to a PC Wiring instructions are described in document number DYNA 316 available from the software download page at www dynaproducts com Copyright 2000 2003 Invensys All Rights Reserved DYNA 326 DPG 2201 001 User Manual Page 19 5 Calibration Instructions 5 1 Basic Adjustments The controller is programmed at the factory with default ID Parameter Name Default Value parameter settings These settings allow the controller to operate SET SPEED A 1000 but will usually require some further adjustments to obtain the PROPORTIONAL best system performance In order to bring the engine up to a 6 INTEGRAL din DERIVATIVE single speed for the first time the installer
4. Copyright 2000 2003 Invensys All Rights Reserved DYNA 326 Troubleshooting Table continued DPG 2201 001 User Manual Page 23 SYMPTOM REMEDY Engine takes too long to reach the set speed Engine Does Not Track Speed Setting Changes Excessive Smoke at Startup Sluggish Response to load changes Engine Instability With No load Engine Instability With Load Engine Unable to Carry Rated Load Load Sharing Does Not Work Droop Does Not Work Improve PID tuning Integral setting is too low Startup Rate setting is too low Accel Rate setting is too low Speed Filter setting is too high Is the LED decimal point blinking If not enter password Is the selected set speed parameter being modified A PID value or an OVG value is too high A PID value is too low or zero Accel Rate is set too low Decel Rate is set too low Improve PID tuning Use a lower Startup Rate setting Use a lower Startup Limit setting Low MPU signal voltage It should read 2 0VRMS minimum Gain too low Improve PID tuning Speed Filter setting is too high Improve PID tuning Speed Filter setting is too low Fuel is restricted Check actuator linkage Battery voltage is too low Improve PID tuning Fuel is restricted Check actuator linkage Battery voltage is too low PID values may be too high causing the governor to over react and make large rapid changes in PWM duty cycle output to the actuator Improve PID tunin
5. Copyright 2000 2003 Invensys All Rights Reserved DYNA 326 DPG 2201 001 User Manual Page 11 3 6 Integral required The integral term is one of the interrelated PID terms that determine how well a DPG 2000 series controller governs the engine s speed The integral gain sets how fast the governor s output changes in response to how long a speed error exists In other words In a proportional only control with constant load there will be a constant speed error that inversely relates to the proportional gain of the system The integral operates to drive this error to zero The integral gain changes the rate at which the error is driven to zero Integral is needed to eliminate speed offsets due to proportional gain and should never be left at zero A zero value is allowed but should only be used as a test when seeking to find the best proportional and derivative values 3 7 Derivative required The derivative term is one of the interrelated PID terms that determine how well a DPG 2000 series controller governs the engine s speed The derivative responds to the rate of change in the speed error This parameter is primarily used to dampen very rapid oscillations resulting from large speed changes A critically damped tuning will always require some derivative A zero value is allowed but should only be used as a test when seeking to find the best proportional and integral values 38 OVG Q Set Speed A required This gain acts as the
6. The DEC decrease key is used to decrease the displayed value In PARAMETER SELECT MODE each press of the DEC key will cause the next lower parameter number to be displayed When the first parameter identification number is reached the next DEC key press will cause the last parameter ID number to be displayed Copyright 2000 2003 Invensys All Rights Reserved DYNA 326 DPG 2201 001 User Manual Page 7 For example If the controller s label lists 32 parameters then pressing the DEC key when the display is blinking the value 01 will cause the display to wrap around to the last parameter listed which in this case is 32 and blink this new value In PARAMETER EDIT MODE each DEC key press will decrease a parameter s current value If the DEC key is held down while in PARAMETER EDIT MODE the value will automatically continue to be decreased at gradually faster and faster rates until the DEC key is released or the parameter s minimum allowed value is reached When the lower two digits display a 00 pressing the DEC decrease key will cause the lower two digits to display a 99 and the hundreds digit will have been decreased by 1 The INC and DEC keys In PARAMETER EDIT MODE the INC and DEC keys are used together to view the value of the upper two digits of a 4 digit number Press and hold both INC and DEC simultaneously to view the value of a 4 digit number s upper two digits note that the left digit s decimal point is turned o
7. three possible settings DISABLED LOCKED and UNLOCKED DISABLED This setting turns off any password protection Use this setting if password protection is not desired This is the default setting as shipped from the factory Entering a value of 99 sets the password protect parameter to the disabled mode When the password protect parameter is selected the LED display will show Pd for 2 seconds indicating the password disabled mode then the value 00 is displayed The user can then edit the value LOCKED This setting means that password protection is active and only parameter viewing is allowed parameter editing is disabled Enter a value of 22 to set password protect to locked mode For 2 seconds after selecting the password protect parameter the LED display will show PE for this mode and the rightmost decimal point will be on no blinking then the value 00 is displayed The user can then edit the value UNLOCKED This setting means that password protection is active but parameter editing is allowed Entering a value of 30 while in LOCKED mode will UNLOCK parameter editing The user is free to edit parameters If there is no keypad activity for 5 minutes the controller returns to LOCKED mode If not already in the UNLOCKED mode the user must get into the UNLOCKED mode in order to enter a 99 to disable password protection 3 25 Over Speed Limit optional This parameter is used to determine the engine speed that will tr
8. 3 5 chapter 3 subsection 5 13 Idle Hold Time 9999 14 Accel Rate T000 11000 The table to the right lists each of the 15 Decel Rate 1000 11000 parameters and their default minimum 16 Startup Rate 1000 11000 e E T7 Startup Limit 7000 T8 Torque Limit 7000 19 Integral Low Limit Integral High Limit Note that several of the parameters have 20 Integral High Limit 99 IntegralLowLimit 99s minimum and maximum values set by 21 Droop other parameters 22 No Load Cal 25 Full Load Cal 7000 24 Password 9 0 9V Dee Oa E e RUE T 7 OSROTERDESMISRUE are shown as magnetic pick up Hertz 26 Set Speed A Min Set Speed A values parameters 2 4 14 16 26 31 27 Set Speed A Max 11000 Set Speed A 11000 Changing the of Flywheel Teeth will 28 Set Speed B Min Set Speed A cause different default values to be Speed uw Bet Speed B di 5 30 Idle Speed Min 10 t0 Tale Speed displayed based on the Hertz to RPM 31 Idle Speed Max 71000 Tdle Speed 11000 pO eee eevee oon as 32 Dutycycle Max below Parameters 2 5 6 7 8 11 and 12 require adjustment while adjustments to the other parameters are optional Copyright 2000 2003 Invensys All Rights Reserved DYNA 326 DPG 2201 001 User Manual Page 9 3 1 fof Flywheel Teeth optional This parameter provides the conversion factor needed by the governor to display speeds as RPM values instead of Hertz values Adjusting this parameter is optional To use
9. IDLE SPEED MIN OPTIONAL 3 31 IDEE SPEED MAX OPTIONAL cre enne eere dob sa e EXE eR ee rh ae ene y og een a aee et apo ca ea aee une 3232 JDUTYCYCLEMAXIMUM OPTIONAL 5 2 3 rrt e RP RR ERRARE RERO RR UR ded 4 UNIVERSAL PST PARAMETER SETUP TOOL eeeeeee estes ete tanen enn ta toten tata a senes ta ton enses totos en ena se nene 18 4 1 UNIVBERSALPSTFEATURES erro RR pe RR TROU RS 18 4 2 UNIVERSAL PST REQUIREMENTS eene nter tree ea ee ee E oe nee ee RE ERE Re Ree Ree i RR RER R E xe ta ea 18 4 3 ACQUIRING UNIVERSAL PS T crece ri tte t re dee er t te Ue pa ge teta e e eed 18 4 4 WARING THE COMM PORT PO Al PC ertet te eer er E REN RETO QR RA ESE 18 5 CALIBRATION INSTRUCTIONS eese ente esten ene stato tonta tnn an nena tonta ense toes tasa anon esto tenen sse tests sonans nea tenen ense nn 19 5 1 BASICCADJUSTMENTS rae eere OP A A Ata Ga 19 5 2 JUNING METHODOLOGY 545 5 reet ertet rie ve t tena IRURE come ie e eee 19 5 3 DROOP CALIBRATION PROCEDURE ende eh rt eer eee e Rer eene e e teen Atta eoe ertet 20 6 INSTALLATION INSTRUCTIONS esee eee eeee este tenta tanan enn ta tanen enia toto estas n sso testata senes essa tenen essen 20 6 1 TERMINAL DESCRIPTIONS Cne a eset eee e e ER RH RARE FEE Rene eer etre RR Ee esata 20 6 2 WIRING DIAGRAM eerte ete ree o e LC cd TEE ERE UE OE RUE EN Lo ER CER eaten 21 7 DIAGNOSTICS amp TROUBLESHOOTING
10. RATE OPTIONAL 3 15 DECEL RATE OPTIONAL n p PP 3 16 STARTUP RATE OPTIONAL ttt tente tette ttt ttt ttt tt tt ttt ttt ttt ttt ttt ttes 3 17 STARTUP LIMIT OPTIONAL tete c tenant temi et eed testen 3 18 TORQUE LIMIT OPTIONAL D ccce ttt ttt ttt tt tt ttt ttt ttt ttt ttt ttt ttes sts Copyright 2000 2003 Invensys All Rights Reserved DYNA 326 DPG 2201 001 User Manual Page 3 3 19 INTEGRAL LOW LIMIT OPTIONAL eerte ttt tret ttt ttt ttt ttt ttt ttt ttt ttt eost 3 20 INTEGRAL HIGH LIMIT OPTIONAL eene tette ttt ttt ttt tt ttt ttt ttt ttt ttt ttt tte sts 3 21 PERCENT DROOP OPTIONAL eene tette ttt tte ttt ttt ttt tt ttt ttt ttt ttt ttt ttt otete ere rs rass 322 NOLOAD CALIBRATION OPTIONAL zs oe 323 FULL LOAD CALIBRATION OPTIONAL ssessssesssssssssesssseessusessuscssuccssuessssesssessusessusessussssesssssessssessnessuecsssessseessseeesssees 324 i PASSWORD OPTIONAL EESE imei EE beg asus dade ie 3 25 OVER SPEED LIMIT OPTIONAL 3 206 SET SPEED A MIN OPTIONAL 3 27 SET SPEED A MAX OPTIONAL s m 2 3 28 SET SPEED B MIN OPTIONAL sesssssssssssssscsssscsssscssssessseessusessusessuscssusssuessssessusessusessussssesssuessssessuessnecsssessseresseeesseees 3 22 SET SPEED BMAX OPTIONAL sscssssssssssssesssecssssessseessseessusessusessuscssuessssessssessusessusessuvsssuvsssuessssessuessuecsssessserssseeesseees 3 30
11. SET SPEED B is set to 11000 then the upper 2 digits will be displayed by the controller as b 0 and the lower 2 digits will display 00 NOTE If the of Flywheel Teeth parameter is used then Set Speed B will be displayed as RPM 3 4 Idle Speed optional IDLE SPEED is the governor s target speed for the IDLE HOLD TIME parameter 13 when the engine is started When the idle hold timer reaches zero the target speed will be become either SET SPEED A or SET SPEED B depending on the state of the SPEED SEL input terminal The default value for IDLE SPEED is 500 MPU Hertz The IDLE SPEED can be set to any value between IDLE SPEED MIN parameter 30 and IDLE SPEED MAX parameter 31 NOTE If the of Flywheel Teeth parameter is used then Idle Speed will be displayed as RPM 3 5 Proportional required The proportional term is one of the interrelated PID terms that determine how well a DPG 2000 series controller governs the engine s speed A speed change creates a speed error the difference between the target speed and the actual speed The proportional gain controls the governor output produced for a specific amount of speed error a higher Proportional value increases error response rate a lower Proportional value decreases error response rate Saturation B5 Een Proportional response Controller output 96 Saturation 0 Error O 0 Each error value produces a unique controller output value
12. e Actuator leads not connected or shorted No Fuel Source Turn on fuel source Battery voltage is low Charge or replace the battery Set speed is lower than crank speed Increase the set speed Startup Rate setting is too low The target speed ramps up too slow Startup Limit is too low limiting the actuator drive signal too much Is the MPU speed signal present It should read 2 0VRMS minimum Adjust magnetic pickup MPU gap Try reversing the MPU leads If a speed signal is present measure actuator output duty cycle If not greater than 5 then restore all parameter values to factory default settings and crank the engine again Engine Over Speeds at Startup Increase the Proportional value Increase the appropriate OVG overall gain value Use the Startup Limit Decrease the Startup Engine Does Not Reach the Set Improve PID tuning Speed e Integral too low or zero Derivative too low or zero PID values are too low A tuning that is too soft can prevent the governor from delivering the needed actuator drive signal to reach the set speed PID values are too high Tuning is too hot or oversensitive to small speed errors which causes the governor to make large rapid changes in actuator drive signal which creates an average signal that is inadequate The Integral Low Limit setting is too high Return the value to the default setting of zero The Integral High Limit setting is too low Return the value to the default setting of 99
13. eeeeee essen ta tenta enta totos tasa annes to ton enn s toten estos an enn es tenen enne enn 22 7 1 DISPLAY CODES eene 7 2 TROUBLESHOOTING TABLE DPG 2201 001 INSTALLATION RECORD amp PARAMETER QUICK REFERENCE eerte 24 Copyright 2000 2003 Invensys All Rights Reserved DYNA 326 DPG 2201 001 User Manual Page 4 1 Governor Specifications The governor s main electrical and mechanical specifications are listed here along with several performance characteristics 1 1 Electrical Operating Voltages 9 VDC minimum to 30 VDC maximum Maximum Controlled Output Current 7 amps Maximum Surge Current 14 amps for ten seconds Terminal Strip with 13 terminals Input Signal from the Magnetic Pickup 2 0 VAC RMS minimum during cranking 1 2 Mechanical Ambient Operating Temperature 40 F to 185 F 40 C to 85 C Sealing Oil water and dust resistant via conformal coating and die cast enclosure 751bs 34kilograms 13 terminal Euro style connector Mechanical Vibration Suitable for mounting per SAE J1455 to 500 Hz 5G amplitude 1 3 Performance Temperature Stability 0 007 Hz 70 C Steady State Speed Band 25 over Ambient Operating Temperature range Engine Speed Measurement Range 10 MPU Hertz to 14 000 MPU Hertz Governing Speed Range 500 MPU Hertz to 11 000 MPU Hertz Copyright 2000 2003 Invensys All Rights Reserved DYNA 326 DPG 2201 0
14. filtering is needed The less rotational mass the more filtering is needed Typically the value 24 works well on small 3 or 4 cylinder engines A value of 16 is recommended for 6 or 8 cylinder engines The following formula can also be used to derive a good starting point for the speed filter value for a given engine application Round the result to the nearest integer The maximum value allowed is 24 _of_flywheel_teeth _of_engine_cylinders 0 75 speed_filter_value 3 13 Idle Hold Time optional The idle hold time specifies how long after starting the engine is to stay at the idle speed before finishing the ramp to the target speed The time value has a resolution of 1 tenth of a second 3 14 Accel Rate optional This rate specifies how fast the governor should increase the engine s speed when a new higher target speed is made active The parameter value is specified in MPU magnetic pickup Hz per second based on the following formula higher speed in Hertz lower speed in Hertz ramp time in seconds accel rate value For example suppose Set Speed A is 3300 Hertz and Set Speed B is 3960 Hertz The governor is currently controlling the engine at 3300 Hertz Set Speed A when Set Speed B becomes the active target speed It is desired that the new speed of 3960 be reached in precisely 2 seconds The following formula determines the value needed by Accel Rate to increase the engine speed from Set Speed A to Set S
15. multiplier on the three PID terms proportional integral and derivative when Set Speed A is selected as the active target speed This gain term is adjustable from 01 to 99 3 9 OVG Set Speed B optional Integral response to constant error gt o X 100 arger p 5 Integral e pe a ae RE r LE smaller o p 50 ae Integral E m value D pene See is cue 096 Time Error Time Derivative response to changes in the rate of deceleration or the rate of acceleration 100 50 Controller output 0 Time The error is sampled at regular intervals When the Rate of change changes red dot the Derivative s impact on controller output changes This gain acts as the multiplier on the three PID terms proportional integral and derivative when Set Speed B is selected as the active target speed This gain term is adjustable from 01 to 99 3 10 OVG Idle Speed optional This gain acts as the multiplier on the three PID terms proportional integral derivative when the Idle Speed is the active target speed The idle speed set point is active only during startup when the idle hold timer is running This gain term is adjustable from 01 to 99 Copyright 2000 2003 Invensys All Rights Reserved DYNA 326 DPG 2201 001 User Manual Page 12 3 11 Gain Factor required The gain factor parameter is used to obtain more range of adjustment from the PID terms In other words if any of the
16. not blinking the selected parameter s value cannot be modified parameter editing is locked and values can only be viewed This is the case when password protection is active and the unlock code has not been entered Read about the Password parameter in the Parameter Reference chapter for more information about using password protection Copyright 2000 2003 Invensys All Rights Reserved DYNA 326 DPG 2201 001 User Manual Page 6 Right digit s decimal point is blinking or on the lower two digits the tens digit and the ones digit of a parameter s 4 digit value are being displayed Left digit s decimal point is on the upper two digits the thousands digit and the hundreds digit of a parameter s 4 digit value are being displayed The upper two digits of a parameter are always view only and can never be modified directly The upper two digits change when the lower digits overflow transition from 99 to 00 or underflow transition from 00 to 99 2 2 Keypad The keypad consists of four pushbuttons named ENTER SELECT INC and DEC The ENTER key The ENTER key is used to exit PARAMETER EDIT MODE and return to PARAMETER SELECT MODE while saving the parameter s new value to nonvolatile memory Nonvolatile memory is where parameter values are stored so that they are remembered even when the governor is not being powered In PARAMETER SELECT MODE pressing ENTER displays the version number of the governor s programming The SEL
17. or password protected The left digit s decimal point is used to indicate that the upper 2 digits of a value the thousands and the hundreds digits are being displayed The upper 2 digits are always view only so the right decimal point does not blink Changes to the upper digits occur when a parameter s lower digits overflow or underflow during editing An overflow occurs when the value 99 is being displayed and the INC key is pressed assuming this is not the parameter s maximum value This will cause the displayed value to become 00 while the non displayed value in the parameter s upper 2 digits will be increased by one You can verify this by pressing both INC and DEC at the same time to view the new value in the upper digits For example If the full 4 digit value of the parameter you are editing is currently 1099 then after pressing the INC key the parameter s new value will be 1100 An underflow occurs when the value 00 is being displayed and the DEC key is pressed assuming this is not the parameter s minimum value This will cause the displayed value to become 99 while the non displayed value in the Copyright 2000 2003 Invensys All Rights Reserved DYNA 326 DPG 2201 001 User Manual Page 8 parameter s upper 2 digits will be decreased by one You can verify this by pressing both INC and DEC at the same time to view the new value in the upper digits For example If the full 4 digit value of the parameter you are editing i
18. this parameter correctly you must know the exact number of flywheel teeth that pass by the magnetic pickup in one revolution of the engine The default value of 0 disables Hz to RPM conversions so all set speeds are displayed in MPU magnetic pick up Hertz Setting this parameter to a value other than zero enables Hz to RPM conversion Adjust this parameter to a value equal to the exact number of pulses that the MPU delivers to the governor in one revolution of the engine to display set speeds in RPM The formula used to convert the magnetic pickup signal from a Hertz value to a RPM value is For example MpuHertz x 60s NumberOfTeeth EngineRPM 3960Hz x 605 S 1800RPM 132Teeth The following derivation of the above formula can be used to convert from RPM to Hertz EngineRPM x NumberOfTeeth 60s MpuHertz 3 2 Set Speed A required SET SPEED A is the governor s target speed when the SPEED SEL input terminal 8 is open and the startup sequence has completed The startup sequence is complete when the target speed and the engine speed reach the set speed When a two position switch is connected between SPEED SEL and 5VDC OUT terminal 13 then an open switch selects SET SPEED A as the governor s target speed If the governor s SPEED SEL input is not used then SET SPEED A is automatically the active target speed after the startup sequence is completed The default value for SET SPEED A is 1000 MP
19. 0 9 30 VDC Input Voltage Range DYNA 70025 Power Flow Gas Valves Smoke Control on Start Up Remote Setu Other Models DPG 2100 Series for Genset Applications P Available DPG 2300 Series for Off road Vehicles i T DPG 2401 Series for EFC Valve Applications Serial Communication Port DPG 2420 Series for Pneumatic Actuators Barber Colman DYNA Products Tel 815 637 3000 P O Box 2940 Fax 815 877 0150 r 1354 Clifford Avenue www dynaproducts com DYNA 326 Loves Park IL 61132 i i nve n syS USA DYNA 326 DPG 2201 001 User Manual Page 2 A WARNING Always disconnect power before making external connections to the control unit to protect against electrical shock A WARNING As a safety measure the engine should be equipped with an independent over speed shutdown device in the event of a failure that may render the governor inoperative NOTE Barber Colman DYNA Products believes that all information provided herein is correct and reliable but reserves the right to update at any time Barber Colman does not assume any responsibility for its use unless otherwise expressly undertaken Table of Contents USER SUEVLUN PT X X P 1 1 GOVERNOR SPECIFICATIONS eese ente ee esten enata ntn ta tan snos ento tenen esses tassa enne to teneas nane n esta ton sanno tenens 4 1 1 jube i 4 1 2 IMIBCITANICATES 5 ctrzezscatececetvessta
20. 01 User Manual Page 5 2 User Interface Operation The user interface has two distinct behaviors that you should familiarize yourself with in order to select parameters and make adjustments to them These behaviors are described in the Operating Modes section below A 4 pushbutton keypad and a 2 digit LED display make up the built in user interface The pushbuttons also called keys are described in the section named Keypad The LED display is described in the section named LED Display Remote access to the governor s parameter settings is available when the governor s COMM port is connected to a computer running our Universal PST application The DPG 2201 001 Technical Manual available from the website www dynaproducts com provides more information regarding the COMM Port and the Universal PST application 2 1 Operating Modes The user interface operates in two modes PARAMETER SELECT MODE and PARAMETER EDIT MODE For each of these modes the keypad and the display have a unique way of operating The following table provides a quick reference to the behavior of the display and the function of each key when a particular operating mode is active PARAMETER SELECT MODE PARAMETER EDIT MODE LED Display The ID number of a parameter LED Display The value of the selected parameter is listed on the governor s label is displayed A blinking decimal point means the blinking on and off value can be modified otherwise the value is view only
21. 1000 engine is fully loaded This parameter is set automatically during the Droop Calibration Procedure PASSWORD is a key used to lock or unlock the capability to modify the parameter values It is also used to activate the droop calibration procedure OVERSPEED LIMIT is the percent over the higher of Set Speed A or Set Speed B that will cause the 100 governor to output the minimum signal to the actuator E t SET SPEED A MIN sets the lowest value allowed for Set Speed A s adjustable range SET SPEED A MAX sets the highest value allowed for Set Speed A s adjustable range 11000 28 SET SPEED B MIN sets the lowest value allowed for Set Speed B s adjustable range A sets S s adj 0 SET SPEED B MAX sets the highest value allowed for Set Speed B s adjustable range 11000 IDLE SPEED MIN is the lowest value allowed for the Idle Speed parameter IDLE SPEED MAX is the highest value allowed for the Idle Speed parameter 11000 DUTYCYCLE MAX sets the absolute maximum amount of drive signal that can be output to the actuator and thus serves as a mechanism for fuel limiting Adjustable in 1 steps Copyright 2000 2003 Invensys All Rights Reserved
22. ECT key The SELECT key is used to enter PARAMETER EDIT MODE from PARAMETER SELECT MODE once a particular parameter has been selected for editing The SELECT key is also used to escape from PARAMETER EDIT MODE and return to PARAMETER SELECT MODE without saving a change in a parameter s value The value a parameter had when PARAMETER EDIT MODE was entered is restored The INC increase key The INC key is used to increase the displayed value In PARAMETER SELECT MODE each press of the INC key will cause the next higher parameter identification number to be displayed When the maximum parameter identification number is reached the next INC key press will cause the first parameter ID number to be displayed For example If the controller s label lists 32 parameters then pressing the INC key when the display is blinking the value 32 will cause the display to wrap around to the first parameter listed and begin blinking the value 01 In PARAMETER EDIT MODE each INC key press will increase a parameter s current value If the INC key is held down while in PARAMETER EDIT MODE the value will automatically continue to be increased at gradually faster and faster rates until the INC key is released or the parameter s maximum allowed value is reached When the lower two digits display a 99 pressing the INC increase key will cause the lower two digits to display a 00 and the hundreds digit will have been increased by 1 The DEC decrease key
23. INC key Increase the parameter ID number INC key Increase the selected parameter s value by one DEC key Decrease the parameter ID number DEC key Decrease the selected parameter s value by one SELECT key Activate PARAMETER EDIT SELECT key Return to PARAMETER SELECT MODE and MODE on the parameter whose ignore changes made to the parameter s value number was blinking ENTER Display the version number of the ENTER Save the parameter s new value and return to governor s programming PARAMETER SELECT MODE INC amp DEC Turn on all LED segments as atest INC amp DEC Use to display the upper digits of values larger Simultaneously Simultaneously than 99 PARAMETER SELECT MODE is the mode used to select a parameter for viewing and editing This mode is active when the 2 digit value being displayed is blinking The value being displayed is a parameter s identification ID number The controller s label lists each user adjustable parameter and its corresponding ID number PARAMETER EDIT MODE is the mode that displays the selected parameter s value and allows the value to be modified This mode is active when the 2 digit value being displayed is on and no longer blinking The value being displayed is the selected parameter s current value The display s decimal points have several different meanings while in PARAMETER EDIT MODE These are described below Decimal point blinking the selected parameter s value can be modified Decimal point
24. PID terms or the Overall gain terms reach their adjustment limits then this value can be modified to provide for more range of adjustment in the PID and OVG terms For example if the PID terms are set to 90 80 and 50 respectively and the Gain Factor is set to 20 then doubling the Gain Factor by setting it to 40 allows the PID terms to be halved to 45 40 and 25 respectively These new settings are equivalent to the previous settings with respect to the governor s tuning response and now allow the PID terms to be adjusted higher if needed 3 12 Speed Filter required This parameter indicates the number of flywheel teeth to use when computing an average engine speed and is used to dampen out speed measurement variations that can make PID tuning difficult But keep in mind the following e Too much filtering will slow down the governor s response to speed changes e Too little filtering can make the governor overly sensitive and tuning difficult There is measurable acceleration and deceleration that occurs between cylinder firings As a general rule less filtering is required the more engine cylinders there are This is because the number of acceleration deceleration cycles increases and these oscillations will have lower amplitude With more cylinders there is less time for the engine speed to slow down before the next cylinder firing Rotational mass also affects the amount of speed signal filtering needed The more rotational mass the less
25. U Hertz SET SPEED A s adjustable range extends from SET SPEED A MIN parameter 26 to SET SPEED A MAX parameter 27 When SET SPEED A values greater than 9999 are displayed the left most digit uses the capital letter A to represent 10000 and uses the lower case letter b to represent 11000 For example If SET SPEED A is set to 10750 then the upper 2 digits will be displayed by the controller as A 7 and the lower 2 digits will display 50 NOTE If of Flywheel Teeth is used then Set Speed A will be displayed as RPM Copyright 2000 2003 Invensys All Rights Reserved DYNA 326 DPG 2201 001 User Manual Page 10 3 3 Set Speed B optional SET SPEED B becomes the governor s target speed when the SPEED SEL input terminal 8 is at 5 volts potential and the startup sequence is complete See the chapter Installation Instructions for details about wiring in a switch between SPEED SEL and 5VDC OUT terminal 13 in order to use SET SPEED B When a two position switch is connected between SPEED SEL and 5 VDC OUT then a closed switch selects SET SPEED B as the governor s target speed The default value for SET SPEED B is 1000 MPU Hertz SET SPEED B s adjustable range extends from SET SPEED B MIN parameter 28 to SET SPEED B MAX parameter 29 When SET SPEED B values greater than 9999 are displayed the left most digit uses the capital letter A to represent 10000 and uses the lower case letter b to represent 11000 For example If
26. USER MANUAL DYNA Programmable Governor for Isochronous Generators With Load Sharing Capability E WCOPRIVZ A ocm wk m GOVERNOR OVERVIEW The DPG 2201 001 is used primarily to govern diesel or gas fueled engines of generator sets This microprocessor based digital controller performs across a wide speed range and allows adjustment of all governor features through the built in user interface spins HR sgg ii E ttt 5 H H j 1 E ERT i Separately programmable Proportional Integral and Derivative gains are provided for tailoring governor response to many engine applications a x 2 perin EL 2 mu Isochronous Speed Control Properly tuned this governor delivers fast engine response to speed or load change while providing precise stable isochronous operation Other adjustments include Acceleration and Deceleration Ramp Rates Startup and Torque Limits Idle Speed Set and Hold Time and more This governor can also provide droop speed Load Sharing amp Droop Operation control with 100 user selectable droop levels User Friendly Operator Adjustable The governor s internal FAILSAFE reacts instantly to loss of the engine speed signal 25 Precision Frequency Control allowing the actuator to return to minimum fuel Superior Temperature Stability DYNA 2000 DYNA 8000 Reverse Battery Protection Ce E DYNA 2500 DYNA 8200 J d DYNA 7000 DYNA 840
27. al term grow more negative is not beneficial Unused negative integration would cause a slower recovery from an under speed condition The integral low limit specifies the PWM duty cycle where the integrator s influence on lowering PID output must stop The default value is 0 The value can be adjusted from 0 to 90 in 1 increments CAUTION Use carefully improper use can prevent the governor from ever reaching the target speed The first line of defense in reducing over speed or under speed errors is a well tuned governor via the PID terms 3 20 Integral High Limit optional The integral high limit prevents integral windup in the positive direction In other words the integral high limit parameter is used to reduce over speed duration after a long or sustained under speed condition was present The high limit helps reduce the duration and amount of engine over speed by maintaining a maximum actuator position Copyright 2000 2003 Invensys All Rights Reserved DYNA 326 DPG 2201 001 User Manual Page 15 When larger PWM duty cycle values do not increase the engine speed any further but a negative off speed measured speed less than the target speed remains letting the Integral term grow more positive is not beneficial Unused positive integration would cause a slower recovery from an over speed condition If an engine overload situation causes the engine speed to remain below the target speed for some period of time then the integ
28. amp amp Ha m FEE ME i 8 9 8 8 18 TORQUE LIMIT 9 E amp g amp amp EZ t t ia e e f 4 22 AWG 14 AWG C D Loc WSIED TWISTED 3 PLCS T BAT MPU 14 AWG Rad TWISTED 20 AWG pu SHIELDED ACT B A SPEED SELECT EC SPEED X NC SPEED V SIG OUT REF IN 22 AWG SHIELDED SUPPLY SUPPLY ILS OR POW R CON b gt 1 22 MAX Copyright 2000 2003 Invensys All Rights Reserved DYNA 326 DPG 2201 001 User Manual Page 22 7 Diagnostics amp Troubleshooting 7 1 Display Codes LED Display Does Not Light Up BAT and BAT leads are reversed Check wiring When Governor Is Powered Battery voltage too low Should measure between 9 and 30 VDC Controller is defective Replace it Unable to Modify Parameters e The parameter s value is at the maximum value allowed e The parameter s value is at the minimum value allowed e A display code is active Refer to the Display Codes section above e Password protection is enabled Enter Password e Keypad Failure replace unit Engine Does Not Start
29. cte aeses svete caucestasentesestsauatshesetacae I EO e E ede ed etre PA EE Pe HE eE PEE oSSe di 4 1 3 gosse d iL H ead 4 2 USER INTERFACE OPERAT ION eeeeee ee een enses tonta tan sn ennt tonta en sateso es tona nsns es to toan esses eo tassa nen ts ton en ense enean 5 2 1 OPERATING MODES P EM 2 2 KEYPAD 2 3 LED DISPLAY 3 PARAMETER REFERENCE 3 1 OF FLYWHEEL TEETH OPTIONAL 3 2 SET SPEED A REQUIRED 3 8 SET SPEED B OPTIONAL ssessssssssssssssessssesssscsssecsssecssssessseessusessusessuscssuessssessssessusessusessussssussssucssstessniessnecssuessseressetesneees 3 4 DLE SPEED OPTIONAL c ecssessssesssssssssessssesssuscssscsssscssssessseessusessusessuscssuessssessssessavessusessussssuessssessstessuessueessuessserssseeesssees 3 5 PROPORTIONAL REQUIRED 3 6 INTEGRAL REQUIRED 3 7 DERIVATIVE REQUIRED a es me e 3 8 OVG SET SPEED A REQUIRED tette ttt ttt ttt ttt ttt ttt ttt ttt ttt subs 3 9 OVG SET SPEED B OPTIONAL tette ttt ttt ttt ttt ttt tbt ttt ttt ttt ttt ots 3 10 OVG IDLE SPEED OPTIONAL ES e E 3 11 GAIN FACTOR REQUIRED ssessssssssssssssesssscsssecsssscssssessseessusessusessusessuesessessssessusessusessussssusssssessstessnessuecsssesssersssetesnsees 3 12 SPEED FILTER REQUIRED eerte ere tere ere a nete i aeter aei De teret rediit 3 13 IDLE HOLD TIME OPTIONAL 3 14 ACCEL
30. et speed is less the 1000 Hertz the startup ramp sequence ends when the target speed 1s reached NOTE When the of FLYWHEEL TEETH parameter is used the ACCEL RATE DECEL RATE and STARTUP RATE parameters are displayed as a RPM quantity per second instead of Hz sec values The given rate formulas can be used to compute rates in terms of RPM values by substituting the Hertz speed values with RPM speed values Copyright 2000 2003 Invensys All Rights Reserved DYNA 326 DPG 2201 001 User Manual Page 14 3 17 Startup Limit optional The startup limit parameter is used to limit the fuel supplied to the engine during startup The default value of 1000 means that the actuator drive signal is allowed to use 100 0 of available current Decreasing the value limits the available drive signal thereby limiting how far open the actuator can go Increasing the value allows the actuator to open further The value assigned to the startup limit parameter is in units of tenth of a percent of the actuator s maximum current feedback reading The governor measures actuator drive signal feedback to obtain an approximation of the amperes of current flowing through the actuator Fuel limiting is achieved by setting the maximum level of electrical current allowed to flow through the actuator during engine startup This feature is useful in reducing smoke when starting diesel engines Note If the value is set too low the engine may not start 3 18 To
31. g Torque Limit is set too low Increase the Torque limit Fuel is restricted Check actuator linkage Measure the ILS input signal to see if the measurement is between 2 375 and 2 625 volts DC Use shielded wiring If the application requires more than 3 of speed change around the set speed then use a DPG 2401 001 controller instead The No Load and Full Load values are not calibrated Perform the Droop Calibration Procedure Difference between No Load and Full Load calibration values is too small Should be 100 for best performance Modify or adjust actuator linkage to increase range of actuator loading If finer droop control is required then use a DPG 2401 001 controller instead Copyright 2000 2003 Invensys All Rights Reserved DYNA 326 DPG 2201 001 User Manual Page 24 DPG 2201 001 INSTALLATION RECORD amp PARAMETER QUICK REFERENCE Customer Phone Distributor Phone Installation Site Installation Date Engine Information Actuator Model of Cylinders ____ Fuel Type Actuator Serial Magnetic Pickup DPG 2201 001 Serial NOTES Record an installation s DPG 2201 001 Setup Information in the User Setting column of the following table PARAMETER NAME parameter definition Default User Value Setting it OF FLYWHEEL TEETH is factor used to display speed as RPM instead of MPU Hertz values a SET SPEED A is the governor s targe
32. he highest value allowed for adjustments of Set Speed A This parameter can be set to any value within the range bordered by current Set Speed A setting and 11 000 Hertz or its RPM equivalent 3 28 Set Speed B Min optional Set Speed B Min is used to set the lowest value allowed for adjustments of Set Speed B This parameter can be set to any value within the range bordered by 10 Hertz or its RPM equivalent and the current value of Set Speed B 3 29 Set Speed B Max optional Set Speed B Max is used to set the highest value allowed for adjustments of Set Speed B This parameter can be set to any value within the range bordered by current Set Speed B setting and 11 000 Hertz or its RPM equivalent 3 30 Idle Speed Min optional This parameter sets the minimum value that the Idle Speed parameter is allowed to have This parameter can be set to any value within the range bordered by current Idle Speed setting and 11 000 Hertz or its RPM equivalent 3 31 Idle Speed Max optional This parameter sets the maximum value allowed for Set Speed A Max Set Speed B Max and Idle Speed 3 32 Dutycycle Maximum optional The Dutycycle Maximum parameter sets the absolute maximum amount of drive signal that can be output to the actuator and thus serves as a mechanism for fuel limiting Fuel limiting is achieved by setting the maximum dutycycle or ontime allowed during one cycle of the PWM pulse width modulation signal controlling the actuator d
33. igger the governor to output minimum fuel The parameter s value is in terms of a percentage over the highest set speed In other words an over speed condition is detected if the engine speed reaches a speed of OVER SPEED LIMIT greater than the highest set speed For example If the highest set speed is 1800 RPM and this parameter is set to 20 then an over speed condition will be detected at 2160 RPM the value that is 20 greater than 1800 Formula 1 20 1800 RPM 2160 RPM The default value of 100 is used to disable over speed detection Use values less than 100 to enable the over speed limit function and set the limit speed to 1 overspeed limit value 100 highest set speed NOTE The governor must be turned off to clear the over speed detection before the engine can be re started Copyright 2000 2003 Invensys All Rights Reserved DYNA 326 DPG 2201 001 User Manual Page 17 NOTE When the of FLYWHEEL TEETH parameter is used the SET SPEED A MIN SET SPEED A MAX SET SPEED B MIN SET SPEED B MAX IDLE SPEED MIN and IDLE SPEED MAX parameters are displayed as RPM values instead of Hertz values 3 26 Set Speed A Min optional Set Speed A Min is used to set the lowest value allowed for Set Speed A adjustments This parameter can be set to any value within the range bordered by 10 Hertz or its RPM equivalent and the current value of the Set Speed A 3 27 Set Speed A Max optional Set Speed A Max is used to set t
34. ion Instructions chapter for more information Copyright 2000 2003 Invensys All Rights Reserved DYNA 326 DPG 2201 001 User Manual Page 16 3 23 Full Load Calibration optional The Full Load Calibration value is learned during the droop calibration procedure and should not be set manually Once calibrated the full load calibration value indicates the percentage of electrical current relative to the measurable maximum that must flow through the actuator to run the engine at the selected set speed when a full load is being applied to the generator The factory default value is 1000 so if droop mode is to be used this parameter must be calibrated The full load calibration value must be greater than the no load calibration value for proper droop operation If after performing the Droop Calibration Procedure the full load calibration value is less than the no load calibration value then the droop function can not be used Some actuators may have a current verses position curve that is incompatible with this controller s method of determining actuator position NOTE This parameter is only modified during the Droop Calibration Procedure See the Calibration Instructions chapter for more information 3 24 Password optional The password protect parameter is provided to protect against inadvertent parameter changes that may occur whenever the keys are pressed and a parameter modification is not intended The password protect parameter has
35. n to indicate that the thousands and the hundreds digits are being displayed Release INC and DEC and now the tens and the ones digits are again being displayed note that the right digit s decimal point is blinking if editing is allowed or just on if editing is not allowed Note not all parameters are 4 digit numbers in which case the upper digits will always display 0 0 zero dot zero In PARAMETER SELECT MODE pressing both the INC and DEC keys at the same time will cause all LED segments to be turned on This serves as an LED test Release the keys to resume displaying the parameter ID number 2 3 LED Display The two 7 segment LED s along with each digit s corresponding decimal point are used to display values and indicate the operating mode of the user interface When the value being displayed by the two 7 segment LED s is blinking PARAMETER SELECT MODE is active When the value being displayed is not blinking the selected parameter s value is being displayed and the user interface is in PARAMETER EDIT MODE The decimal points further indicate which half of a 4 digit value is being displayed and whether editing is allowed The right digit s decimal point is used to indicate that the lower 2 digits of a value the tens and the ones digits are being displayed When the right decimal point is blinking it means that the value can be modified using the INC key or the DEC key Not blinking means that editing is not allowed
36. peed B in 2 seconds Set Speed B Set Speed A N seconds accel rate value in Hertz per second 3960 3300 2 330 Hertz per second Copyright 2000 2003 Invensys All Rights Reserved DYNA 326 DPG 2201 001 User Manual Page 13 3 15 Decel Rate optional The Decel Rate specifies how fast the governor should decrease the engine s speed when a new lower target speed is made active The parameter value is specified in MPU magnetic pickup Hertz per second based on the following formula higher speed in Hertz dower_speed_in_Hertz ramp_time_in_seconds decel_rate_value For example suppose Set Speed A is 4170 Hertz and Set Speed B is 3475 Hertz The governor is currently controlling the engine at 4170 Hertz Set Speed A when Set Speed B becomes the active target speed It is desired that the new speed of 3475 be reached in precisely 1 5 seconds The following formula determines the value needed by Decel Rate to decrease the engine speed from Set Speed A to Set Speed B in 1 5 seconds Set Speed A Set Speed B N seconds decel rate value in Hertz per second 4170 3475 1 5 2 463 Hertz per second 3 16 Startup Rate optional This parameter is used to achieve a smooth controlled engine start On diesel engines this feature is also useful for minimizing exhaust smoke at startup When used in combination with the Idle Speed and Idle Hold Time a brief warm up cycle can be programmed The
37. ral portion of PID output would grow larger than otherwise needed would windup So when the load is removed the engine may over speed because it takes time for the integral portion of PID output to shrink or unwind This is where reducing the Integral Limit High value can help by preventing excessive windup in the PID output s integration term The integral high limit specifies the PWM duty cycle where the integrator s influence on raising PID output must stop The default value is 99 The value can be adjusted from 99 down to 10 in 1 increments CAUTION Use carefully improper use can prevent the governor from ever reaching the target speed The first line of defense in reducing over speed or under speed errors is a well tuned governor via the PID terms 3 21 Percent Droop optional The percent droop parameter is used to select droop mode operation and specify the percentage of droop required When the percent droop parameter is set to zero the default setting then droop mode is not active Droop mode is active when this parameter is set to any value from 1 to 100 which corresponds to 0 1 to 10 0 droop The following formula determines the no load droop speed selected set speed 1000 value of b DROOP 1000 no load droop speed For example If 596 droop is desired set the percent droop value to 50 Now if the selected set speed is 1800 RPM then the no load droop speed will be 1800RPM 1000 50
38. rive circuit The value assigned to the dutycycle limit parameter is a percentage and is limited to values in the range 10 to 95 The default value is 95 Copyright 2000 2003 Invensys All Rights Reserved DYNA 326 DPG 2201 001 User Manual Page 18 4 Universal PST Parameter Setup Tool The Universal PST is a Microsoft Windows application available from Barber Colman DYNA Products that enables you to adjust parameter settings and monitor governor operation when a PC is connected to the governor through the built in COMM port 4 Universal PST Features Universal PST for DPG features include automatic configuration to each DPG when communications established read write access to all of a DPG s programmable parameters and features display of each parameter s default minimum and maximum values diagnostics utilizing automatic refresh of DPG status saving and reloading DPG setup information to and from a file for reuse single button read to get the current values of all parameters single button write to program a DPG with previously saved setup values engine speed monitoring via a chart recorder to aid in tuning the governor saving chart recorder data to a Microsoft Excel compatible file help information on each of the governor s parameters help information on using the Universal PST 4 20 Universal PST Requirements The program requires an Intel Pentium class machine running Microsoft Windows 98se NT4
39. rque Limit optional The torque limit parameter is used to limit the fuel supplied to the engine during heavy generator loads or generator overloads The default value of 1000 means that the actuator drive signal is allowed to use 100 0 of available current Decreasing the value limits the available drive signal thereby limiting how far open the actuator can go Increasing the value allows the actuator to open further The value assigned to the torque limit parameter is in units of tenth of a percent of the actuator s maximum current feedback reading The governor measures actuator drive signal feedback to obtain an approximation of the amperes of current flowing through the actuator Fuel limiting is achieved by setting the maximum level of electrical current allowed to flow through the actuator during normal operation Note If the value is set too low the engine will not be able to carry its rated load 3 19 Integral Low Limit optional The integral low limit prevents integral windup in the negative direction In other words the integral low limit parameter is used to reduce under speed duration after a long or sustained over speed condition was present The low limit helps reduce the duration and amount of engine under speed by maintaining a minimum actuator position When smaller PWM duty cycle values do not reduce the engine speed any further but an off speed measured speed greater than the target speed remains letting the Integr
40. s currently 1800 then after pressing the DEC key the parameter s new value will be 1799 When values exceeding 9 999 are to be displayed the controller uses the hexadecimal numbering system to represent the value of the thousands Decimal to Hexadecimal position Conversion Chart Example 1 The desired set speed is 10 069 Hertz The upper two digits Value Equivalent displayed by the controller will be A 0 and the lower 2 digits displayed will be 69 a ay a ae Example 2 The desired set speed is 10 972 Hertz The upper two digits 0O O B D displayed by the controller will be A 9 and the lower 2 digits displayed will be 72 3 Parameter Reference This chapter provides information DPG 2201 001 Parameter List regarding each parameters function T Default contains 32 subsections Each subsection 1 of Flywheel Teeth provides information about a single 2 Set Speed A 1000 Set Speed A Min Set Speed A Max parameter 3 Set Speed B 1000 Set Speed B Min Set Speed B Max 4 Idle Speed Idle Speed Min Idle Speed Max ao Subsection numbering corresponds to the 4 Tntegra E E E E parameter numbering on the governors 7 Derivative 25 o M w label to make it easier to locate 8 OVG Set SpeedA 20 1 9 information about the parameter of 9 OVG Set SpeedB 20 ot 8D eae eorne Paea 1n ONG D m Speed Ee ae ee rd Gain Factor q 99 O sar ee one 12 Speed Filter subsection
41. startup rate specifies how fast the governor should increase the engine speed when the engine is started The rate value indicates Hertz per second The formula to use for determining a precise Startup Rate is shown below final target speed in Hertz crank speed in Hertz ramp time in seconds startup rate value The governor increases the engine speed from the engine s crank speed to the active target speed at the rate specified The governor will bring the engine to the Idle Speed for the Idle Hold Time then continue increasing the engine speed at this same ramp rate until the engine reaches the selected target speed Set Speed A or Set Speed B Exception 1 In cases where the target speed is less then the Idle Speed and the Idle Hold Time is nonzero the startup ramp sequence ends when the Idle Speed is reached Then the Decel Rate is used to ramp the engine speed down to the target speed from the Idle Speed The ramp up will pause at 1000 MPU Hz until the governor senses an MPU signal greater than 1000 Hertz This prevents the startup ramp from reaching completion before the engine has even started The governor considers MPU frequencies below 1000 Hertz as indicating that the engine is cranking but has not yet started MPU frequencies above 1000 Hertz are taken to indicate that the engine has started and the governor will increase the engine speed until the selected set speed is reached Exception 2 In cases where the targ
42. t speed when the controller s SPEED SEL terminal is open 1000 SET SPEED B is the governor s target speed when the SPEED SEL terminal is at 5 volts DC 1000 4 500 IDLE SPEED is the governor s target speed for the IDLE HOLD TIME when the engine first starts If the value of the IDLE HOLD TIME parameter is zero the IDLE SPEED is not used s PROPORTIONAL isthe gain applied tothe speeder 323 6 INTEGRAL is the gain on the reset time and is used to eliminate the speed offset due to i in 50 DERIVATIVE is the gain on the response to the rate of speed change 25 8 OVG SET SPEED A is a multiplier used on the three PID terms when Set Speed A is the target speed 20 OVG SET SPEED B is a multiplier used on the three PID terms above when Set Speed is the target 20 lt 9 OVG Q IDLE SPEED is a multiplier used on the three PID terms above when Idle Speed is the target 20 GAIN FACTOR is a multiplier applied to the PID terms that can be used to give those terms more range 20 SPEED FILTER is the number of flywheel teeth to use when computing an average engine speed 16 13 IDLE HOLD TIME is the period of time that the engine will remain at the Idle Speed during the startup sequence before ramping to either Set Speed A or Set Speed B ACCEL RATE is the rate in MPU Hertz or RPM per second used to ramp to a new higher target speed 1000
43. te error in the engine s speed and help decrease error recovery time Integration works on 7 The overall gain can be increased to improve the sum of the errors response time while keeping the ratios of the PID accumulated over time terms relative to each other constant The Derivative works on the Instantaneous Rate of Change in the amount of error The Proportional term s output is Error e During each of the steps 3 through 6 you need to disturb the system by adding and removing a load from the engine to check the governor s response to the load transition START WITH SMALL LOADS Note that without integral a speed error may persist after a load on load off transition So during steps 3 5 you should temporarily increase the integral to get the engine speed back to the set speed then reset the integral to a lower value again while working to find good proportional and derivative values Repeat steps 3 7 as needed to find a Proportional value Integral value and a Derivative value that work well with a variety of overall gain values and different load transients Copyright 2000 2003 Invensys All Rights Reserved DYNA 326 DPG 2201 001 User Manual Page 20 5 3 Droop Calibration Procedure To use Droop a calibration sequence must be done first The calibration sequence is as follows Make sure the engine is running at the selected set speed and the governor is tuned Enter a value of 41 into the Password parameter 24 to allo
44. tiometer and a supporting controller 6 Installation Instructions 6 1 Terminal Descriptions Name Funtion 00 6 MPU Magnetic Pickup ground i O 8 SPEEDSEL Digital Input used to select the target setspeed 9 ILS SIGNAL _ ILS input used to adjust speed amp 360 __ _ 5VDC OUT Supply voltage for the digital inputs Copyright 2000 2003 Invensys All Rights Reserved DYNA 326 DPG 2201 001 User Manual Page 21 6 2 Wiring Diagram For Terminal Descriptions see the table on the previous page 5 60 MAX 5 05 NOM 4X 4 22 COMM ING SELECT iles parts DPG 2201 001 SERIALS X00 X KOK I OF FLYWHEEL TEETH INTEGRAL LOW LIM 3 125 NOM 2 SETSPEED A 20 INTEGRAL KIGH LIM 3 SETSPEED B 21 DROOP 4 IDLE SPEED 22 NO LOAD CAL 5 PROPORTIONAL 22 FULL LOAD CAL DEC ENTER 8 INTEGRAL 24 PASSWORD LF eR 7 DERIVATIVE 28 OVER SPEED LIMIT COLMAN 3 92 MAX 8 OVG SETSPEED A 26 SETSPEED A MIN 9 OVG SETSPEED amp 27 SETSPEED A MAX See 10 O G IDLE SPEED 28 SETSPEED B MIN 11 GAIN FACTOR 29 SETSPEED B MAK 12 SPEED FILTER 36 MIN SETSPEED 13 IPLE HOLD TIME Si MAX SETaPEED za ieee te v 23 bk 10 STARTUP RATS Ee gt i 5 do 8 47 STARTUP LIMIT 5 89
45. w editing of the droop parameters Step 3 Select the DROOP parameter 21 and adjust its value while the engine is running with no load applied The engine speed will increase to selected_set_speed 1000 value_of_ _DROOP 1000 Step 4 Allow the engine to stabilize at the no load droop speed then press the controller s ENTER key to set the percent droop No Load Calibration is now complete Now apply full load to the engine and allow the speed to stabilize Assumes the governor was previously tuned Full Load Calibration is now complete Remove the load from the engine The engine speed will increase to the no load droop speed Droop Calibration is complete After droop calibration the difference between the No Load Cal and Full Load Cal parameter value should be greater than 100 for best operation of droop The droop function may still work for smaller differences but with less accuracy You may be able to get some improvement by modifying or adjusting actuator linkage or adding springs The goal is to achieve a wider range of measured current change through the actuator from no load to full load If the calibrated range is too small then droop may not work at all The actuator position sensing method used by this controller does not work with all actuators A different actuator may be required or a different system solution altogether may be needed by your application such as an actuator with a position feedback poten
46. will probably need to 8 OVG SET SPEED A make adjustments to the parameters shown in the table GAIN FACTOR note 1 m SPEED FILTER note 2 The parameters listed in the table are the primary ones to modify to get the governor tuned and the engine running smooth It is Note 1 Modify Gain Factor only if you run out of adjustment in a PID or OVG term recommended that you work with them first and leave all the Note 2 For the Speed Filter typically the value 24 other parameters at their default values until you are satisfied works well on small 3 or 4 cylinder engines A value of with the basic engine tuning 16 is recommended for 6 or 8 cylinder engines 5 2 Tuning Methodology Once the engine is running the following procedure may be used to discover more optimum values for PID and the overall gain OVG parameters The goal would be to find PID values that allow the controller to govern the engine well at a variety of different speeds and loads while only requiring gain adjustment at those different speeds Step 1 Set the integral and derivative terms to 0 2 Set the overall gain low lt 20 3 Increase the proportional term until you get continuous oscillations greater than 2Hz unique for each 4 Reduce the proportional term by 25 to 50 measured error 5 Now experiment with small value changes in the derivative to dampen out ringing in response to load transients 6 Add some integral to eliminate any steady sta
Download Pdf Manuals
Related Search