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Woodward Electronic Governor Control Operators Manual

1. 82 51 636 7080 Poland 48 12 618 92 00 United States 1 970 482 5811 Engine Systems FACILITY PHONE NUMBER Brazil 55 19 3708 4800 China 86 512 6762 6727 Germany Stuttgart 49 711 78954 0 India 91 129 4097100 Japan 81 43 213 2191 Korea 82 51 636 7080 The Netherlands 31 23 5661111 United States 1 970 482 5811 Turbine Systems FACILITY PHONE NUMBER Brazil 55 19 3708 4800 China 86 512 6762 6727 India 91 129 4097100 Japan 81 43 213 2191 Korea 82 51 636 7080 The Netherlands 31 23 5661111 United States 1 970 482 5811 You can also contact the Woodward Customer Service Department or consult our worldwide directory on Woodward s website www woodward com support for the name of your nearest Woodward distributor or service facility For the most current product support and contact information please refer to the latest version of publication 51337 at www woodward com publications Woodward 43 Manual 36526F DPG 21XX 00X Digital Controllers Technical Assistance If you need to telephone for technical assistance you will need to provide the following information Please write it down here before phoning General Your Name Site Location Phone Number Fax Number
2. Prime Mover Information Engine Turbine Model Number Manufacturer Number of Cylinders if applicable Type of Fuel gas gaseous steam etc Rating Application Control Governor Information Please list all Woodward governors actuators and electronic controls in your system Woodward Part Number and Revision Letter Control Description or Governor Type Serial Number Woodward Part Number and Revision Letter Control Description or Governor Type Serial Number Woodward Part Number and Revision Letter Control Description or Governor Type Serial Number If you have an electronic or programmable control please have the adjustment setting positions or the menu settings written down and with you at the time of the call Woodward 44 We appreciate your comments about the content of our publications Send comments to icinfo woodward com Please reference publication 36526 AN woOopwaptp PO Box 1519 Fort Collins CO 80522 1519 USA 1000 East Drake Road Fort Collins CO 80525 USA Phone 1 970 482 5811 e Fax 1 970 498 3058 Email and Website www woodward com Woodward has company owned plants subsidiaries and branches as well as authorized distributors and other authorized service and sales facilities throughout the world Complete address phone fax email information for all locations is available on our website 2010 1 Skokie
3. Remote Options Options SS Speed Model No Set INC and 7 wire 12 pin Magnetic Ignition Speeds an Euro Molex Pickup Sense DEC DPG 2101 00X x 1 idle DPG 2145 00X S 2 idle DPG 2146 00X 1 idle DPG 2155 00X 2 idle K Electrical Operating Voltage Range 9 30 Vdc Rated Output Current 7 A Maximum continuous Maximum Surge Current 14 A not to exceed ten seconds Terminal strip with 7 Euro style Connections terminals or a quick connector with 12 pins Input Signal from Magnetic Pickup 2 0 VAC RMS minimum during cranking Input Signal from Engine s 40 V minimum during cranking Ignition System All cabling for these controllers is limited to less than 30m 98 4 Power cabling is limited to less than 10m 32 8 in total length See wiring diagrams for specific cable types required Mechanical Ambient Operating Temperature 40 F to 185 F 40 C to 85 C Oil water and dust resistant via Sealing conformal coating and die cast enclosure Weight 10 oz 284 g Woodward 2 Manual 36526F DPG 21XX 00X Digital Controllers Performance Steady State Speed Band 25 over ambient operating temperature range Engine Speed MPU Measurement Range 10 MPU Hertz to 14 000 MPU Hertz Governing Speed Range with MPU 500 MPU Hertz to 11 000 MPU Hertz Engine Speed Ignition Measurement Ran
4. Manual 36526F DPG 21XX 00X Digital Controllers Tuning View The Tuning View panel is displayed only after pressing the lt View Chart gt button The Tuning View panel is part of the Chart View display mode To modify a tuning parameter s current Tuning View value it must first be selected Do this by double clicking the left mouse button on a Name Value cell in the table that is at the intersection of Proportional 50 the parameter s row and the Value Integral 20 column Derivative 10 Overall Gain 10 The selected cell will be highlighted and aac i the value can now be modified When Se a Se artup Limit 100 done modifying the value press the Torque Limit FTN computer keyboard s lt Enter gt key to EE o transmit the new value to the controller Integral High 100 Chart Recorder The chart recorder is part of the Chart View display mode Each time Chart View is entered the last used Data File is reset the Vertical Scale defaults to 0 Hz to 12000 Hz and the Horizontal scale defaults to 20 seconds The chart recorder s display characteristics are configured using the Vertical Scale options the Horizontal Scale options and the Chart Recorder Signal Filtering options Vertical Scale Hertz Horizontal Scale in seconds Ze 0 to 12000 Hz Cd Ee 60 anre 200 10 5 C J o te sooo He 0 0 ess Recorder Signal Filtering C t 10 0f 1000 Hz Min CCCCCCC Max The Vertical Scale options provide three different w
5. eat 7 8 9 a a D Lf inc para 1 2 3 EAA pe act x LD 8 22 ga SHIELDED Zk 16 go ATX TWISTED KS GND 18 22 go BAT SHIELDED Figure 2 Wiring Diagram for DPG 2145 001 and DPG 2145 002 Controllers Connect the MPU shield at the controller end only Connecting the shield at the MPU source end could introduce noise due to ground loops and also disable the reverse battery protection feature To prevent damage to the controller make sure that it is wired in accordance with the wiring instructions and diagrams in this manual N O TI OF e Do not tin the leads before placing them into the terminals Ensure the terminals are tightened properly to secure wires Woodward 33 Manual 36526F DPG 21XX 00X Digital Controllers DPG 2146 00X Dimensions are in inches 4 520 4 015 NEW 230 015 2 062 WEW 230 015 4 062 015 2304 0157 7 CS PART NO SERIAL NO 1 WIDE W WOODWARD IGN TACH 4X 22
6. 20 3 Increase the proportional term until you get continuous oscillations greater than 2 Hz Reduce the proportional term by 25 to 50 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 state error in the engine s speed and help decrease error recovery time 7 The overall gain can be increased to improve response time while keeping the ratios of the PID terms relative to each other constant Woodward 27 Manual 36526F DPG 21XX 00X Digital Controllers 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 controller 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 Therefore during steps 3 5 you should temporarily increase the integral to get the engine speed back to the set speed and 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 The Derivative works on the Instantaneous Rate of Change in the amount of error The Proportional term s output is unique for each measured error Integration works
7. 23 Set Speed B Min optional 15 3 24 Set Speed B Max optional 15 3 25 Idle Speed Min optional 15 3 26 Idle Speed Max optional 15 3 27 Duty Cycle Limit optional 16 3 28 Startup Speed required ccceeececeeeeseeeeeeeeeeeeeeeeeeeeeseaeeeeeeeeeeeeeeas 16 3 29 Startup Duty Cycle optional 16 Woodward i Manual 36526F DPG 21XX 00X Digital Controllers Contents cont d CHAPTER 4 UNIVERSAL PST 22 2 00ccceccssncnesccncssecersnsnnnecnssrnceenssennessccenenene 18 JMEFOCU CLOM mAn EA E A E A T 18 FeatUre Siid iiaii iii ii a iii LEERE 18 System Requirements cccccceeeeeceeeeeeeeeeeeeeceeeeeeaaeseeaeeseeeesaeeeeaaeseeneessaees 18 Acquiring Universal D I 19 Installing Universal D I 20 Wiring the COMM Port to a PC eccceesceceeeeeeeeeeeeeeeeeeeeeeeeesaeeeeeeeeeneeeaas 20 Communications Error eeecceesececesseecececeeeceeecseeeeeeseeeeeeeseeeeeesseeeaeesseeeaees 21 Universal PST User Interface Overview ssseseeseeseseieeresrresrreerrrerresrren 21 Universal PST Menu Wems eeeeaeseeeeeseaeeesaaeseeeeeeeeeeee 23 Parameter SOUP BEE 23 Parameter EMP EE 24 Synchronizing Universal PST with a DO 24 DLALUS VIGW E IEE E E EEE A deed ege 24 TUNDO VOW anses a S S E 25 Chart RECOPOR ostessa oani eannan NAE NN A AEN ARANE RNANA 25 Engine Speed Data CGollecton rne rnn nenntu rernreennsn nns 26 CHAPTER 5 CALIBRATION INSTRUCTIONS cscccssseseeeeesseneeeensseneeeeneeneeees 27 Basic AdjUStMOmint isc
8. C Program Files wWoodward Universal PST MPU_ Pause Chart Data Reset View Table NOTE Pressing a button means positioning the mouse pointer over the button and clicking the left mouse button Woodward 22 Manual 36526F DPG 21XX 00X Digital Controllers Universal PST Menu Items Use the File menu to l e Open a previously saved setup data file File Men Port Help e Save setup data to a file EE Save setup data to a file e Send setup data to the default printer Ee e Exit the program Se Tir Default h 3736 1000 Use the View menu to e Select Parameter Table view Table Vi ew File view Port Help v Parameter Table e Select Chart Recorder view Chart Chart Recorder fameter Setu View Name Yalue_ Default 1 Number of Teeth 0 0 Use the Port menu to e Select the PC s serial port that is File View Port Help connected to the DPG 2000 E DPC come coms comM4 Value _ Default I 0 0 1 Number of Teeth Use the Help menu to access e Help on the Universal PST for DPG e Help on the DPG 2000 product that is File View Port Help currently in communication with the PC Setup Tool Help DPG 22 e Information about the Universal PST for E Geeemer Help Contents x e Parameter Definitions DPG application Na 1 Numberc About 2 Set Spee Parameter Setup The Parameter Setup panel displays a table where each row shows the Name of a user programmable parameter its c
9. Chapter 3 Parameter Reference EE This chapter provides information regarding each of the parameters that can be adjusted when a computer is connected to the controller via the COMM port Universal PST described in the following chapter is required to make adjustments to the parameters described in this chapter with the exception of Set Speed A Set Speed B and OVG Set Speed A It contains 29 subsections Each subsection provides information about a single parameter The following tables list each of the parameters and their default minimum and maximum values Several of the parameters have minimum and maximum values set by other parameters Speed and Rate values are shown as Hertz values The parameter list provides information regarding each of the parameters that can be adjusted when a computer is connected to the controller via the COMM port and the Universal PST software The COMM port is intended only for configuration and periodic service Do not leave a computer and or COMM cable connected to the COMM port Woodward 5 Manual 36526F DPG 21XX 00X Digital Controllers DPG 2101 00X amp DPG 2146 00X Parameter List PARAMETER LIST FOR DPG 2101 00X MPU amp DPG 2146 00X IGNITION These controllers use the 7 terminal Euro style screw terminal connector PARAMETER NAME DEFAULT MINIMUM MAXIMUM 1 No o
10. Set Speed B Max 10 OVG Idle Speed 20 20 1 399 30 Idle Speed Min 11 Gain Factor mm 20 1 39 31 Idle Speed Max 12 Speed Filter 16 16 1 24 32 Duty Cycle Limit 13 Idle Hold Time 0 o O 9999 33 Startup Speed 14 Accel Rate 1000 1000 1 11000 34 Startup Dty Cycl 15 Decel Rate 1000 o 1 11000 16 Startup Rate 1000 1000 1 11000 17 Startup Limit 1000 o 0 1000 18 Torque Limit 1000 1000 o 1000 19 Integral Low 0 0 H 39 20 Integral High m om 0 99 i i Hardware 1 View Status Write All Software 30 View Chart 1000 1000 0 100 10 11000 10 11000 0 0 0 10 1000 10 1000 10 500 10 10 Ww 1000 99 100 1000 11000 1000 11000 500 11000 95 11000 95 WOODWARD OKO In Table View the user can e View the current values for all user programmable parameters in the Parameter Setup panel e Edit a parameter s value by double clicking on a cell in the Value column of the table e Press the lt Read All gt button to refresh the values displayed in the Parameter Setup panel e Press the lt Write All gt button to transmit setup values to the controller e Press the lt View Status gt button to display read only parameters in the Status View panel Woodward 21 Manual 36526F DPG 21XX 00X Digital Controllers Press the lt View Chart gt button to set the display mode to Chart View e Select items from the menu Read All Hardware 1 Write All Softwar
11. THRU Figure 3 Wiring Diagram for DPG 2146 001 and DPG 2146 002 Controllers 1 Connect the MPU shield at the controller end only Connecting the shield at the MPU source end could introduce noise due to ground loops and also disable the reverse battery protection feature Woodward 34 Manual 36526F DPG 21XX 00X Digital Controllers DPG 2155 00X Dimensions are in inches Dimensions in brackets are millimeters 231 015 LX 219 015 586 2 780 211 EE 1 NEG 5 86 0 38 A J PART NO PPOK 2155 00X REV DEC SPEED INC SERIAL N CNED E aim WOODWARD act a Bee BaT 7 Z pat 1 2 act 7 18 22 AWG wa LDED 4 DAI SET SPD 1 SPD 2 Figure 4 Wiring Diagram for DPG 2155 001 and DPG 2155 002 Controllers 1 Connect the MPU shield at the controller end only Connecting the shield at the MPU source end could introduce noise due to ground loops and also disable the reverse battery protection feature To prevent damage to the controller make sure that it is wired in accordance with the wiring instructions and diagrams in this manual N e TI CE e Do not tin the lead
12. any connectors antistatic protective bags on all electronic modules packing materials that will not damage the surface of the unit at least 100 mm 4 inches of tightly packed industry approved packing material a packing carton with double walls a strong tape around the outside of the carton for increased strength To prevent damage to electronic components caused by improper handling read and observe the precautions in N el TI C E Woodward manual 82715 Guide for Handling and Protection of Electronic Controls Printed Circuit Boards and Modules Replacement Parts When ordering replacement parts for controls include the following information e the part number s XXXX XXXX that is on the enclosure nameplate e the unit serial number which is also on the nameplate Woodward 42 Manual 36526F DPG 21XX 00X Digital Controllers Engineering Services Woodward offers various Engineering Services for our products For these services you can contact us by telephone by email or through the Woodward website e Technical Support e Product Training e Field Service Technical Support is available from your equipment system supplier your local Full Service Distributor or from many of Woodward s worldwide locations depending upon the product and application This service can assist you with technical questions or problem solving during the normal business hours of the Woodward location you contact Emergency assist
13. conversion DPG 21XX 002 Models Adjusting the No of Flywheel IMPOR TANT Teeth parameter is prohibited while the engine is running Adjust this parameter to a value equal to the exact number of pulses seen by the controller in one revolution of the engine to display set speeds in RPM The formula used to convert the speed signal from a Hertz value to a RPM value is _ Hertz lt 605 eener Pulses _ per_ rev For example 39607 x 60s f score 132Pulses_ per_rev The following derivation of the above formula can be used to convert from RPM to Hertz EngineRPM x Pulses _ per_ rev 60 s Hertz DPG 2101 00X and DPG 2155 00X Models To use this parameter correctly on controllers sensing engine speed with a magnetic pickup you must know the exact number of flywheel teeth that pass by the magnetic pickup in one revolution of the engine DPG 2145 00X and DPG 2146 00X Models To use this parameter correctly on controllers sensing engine speed via ignition pulses you must know the exact number of ignition pulses that occur in one revolution of the engine 3 2 Set Speed A required This parameter is adjustable both from the controller s DEC and INC keys and by using the Universal PST application However when the value is changed using the controller s keypad the value displayed by the Universal PST does not automatically update To refresh the value displayed on
14. i cciteeeccete hctiet ache eiee cea EEN Eed eines dane 27 Tuning Methodology EEN 27 Startup Eegen due Gee Mess KEE teense cet ene edited cert 29 CHAPTER 6 INSTALLATION INSTRUCTIONS cccecssseseeeeesseneneesseneneeneeneenes 30 Recommended Mounting sssseessssesesrresssrnesssrnesrnnnnstnnneennnnnntennnnnnnnnnnnnnnnnnnnnnnan nnna 30 Terminal Descriptions ccccescccceesscceeeeeeeceeeeeseeeeeeseceeeeaaeeeeesaeaeeeseseeeeeeeeeaeenees 30 ME CO ELE 30 PPG 2214 EE 30 PP G21 EEN 31 DPG 2155 00X nirin iian nan apccnussncensieessceavasteeeses aR ge 31 Wima Dadamo EE 32 MECHELEN 32 PPG 221 ET 33 PP G21 el 34 NI E EE ET 35 Centralized Suppression cccccsceceeeeceeeeeeaeeeeeeeceeeeecaaeeeeaaeseeeeseaeessaeeeeneeeeaees 36 CHAPTER 7 DIAGNOSTICS amp TROUBLESHOOTING tcsccsssstteeeesseneneenseneenes 38 S ll Te te EE 38 Troubleshooting ME Le ET 38 CHAPTER 8 SERVICE OPTIONS ccccsccecssnneessccniesecessnesnecntenscsestscnnasseneaseene 40 Product Service Option 40 Woodward Factory Servicing Option 41 Returning Equipment for Repair 42 Replacement E 42 Engineering Service EE 43 How to Contact WoOdWatd ccccccccececeeeeeeneeeeeeeeeeeeeseaeeseaaeseeeeeseaeeesaeeeeaeeteeeeess 43 Technical ASSISTANCE misas siasii tasenn a aa Eaa a A e a 44 Woodward ii Manual 36526F DPG 21XX 00X Digital Controllers Regulatory Compliance Declaration of Conformity DPG 2145 amp DPG 2155 DECLARATION OF CONFORMITY M
15. not reduce the engine speed any further but an off speed measured speed greater than the target speed remains letting the Integral 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 Woodward 13 Manual 36526F DPG 21XX 00X Digital Controllers Use carefully as improper use can prevent the controller N e TI C E from ever reaching the target speed The first line of defense in reducing over speed or under speed errors is a well tuned controller via the PID terms 3 18 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 overspeed duration after a long or sustained under speed condition was present The high limit helps reduce the duration and amount of engine overspeed by maintaining a maximum actuator position 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
16. on the sum of the errors accumulated over time Woodward 28 Manual 36526F DPG 21XX 00X Digital Controllers Startup Sequence The following example describes the DPG 21XX 00X startup sequence Startup Sequence Example IDLE HOLD 1 ke TIME 100 gt I j j I SPEED 1500 Hz s l I I I ACCEL RATE 500 Hz sec Speed in Hertz __ STARTUP RATE 250 Hz sec M rr STARTUP SPEED 500 Hz a 15 20 25 30 35 Time in seconds Engine cranking begins at point A After a short time the engine starts and at point B the engine speed exceeds the STARTUP SPEED the initial target speed and the controller now considers the engine to be running The controller s startup sequence begins at point B by ramping the target speed up from the STARTUP SPEED at the STARTUP RATE In this example the STARTUP SPEED is set to 500 Hertz the STARTUP RATE is set equal to 250 Hertz per second and the IDLE SPEED is set to 1500 Hertz It will take 4 seconds for the target speed to ramp up 1000 Hertz IDLE SPEED minus STARTUP SPEED and reach point C This example uses the IDLE HOLD TIME and has it set to 100 tenths of a second so the target speed will be held at the IDLE SPEED 1500 Hertz in this example for 10 seconds At point D the IDLE HOLD TIME has elapsed and the target speed is ramped up at the ACCEL RATE In this example the ACCEL RATE is set e
17. parameter settings These settings allow the controller to operate but usually require some further adjustments to obtain the best system performance In order to bring the engine up to a single speed for the first time the installer will probably need to adjust the parameters shown in the table below The parameters listed are the primary ones to modify to get the controller tuned and the engine running smoothly It is recommended that you work with them first and leave all the other parameters at their default values until you are satisfied with the basic engine tuning Parameter Name Default Value SET SPEED A 1000 PROPORTIONAL 25 INTEGRAL 50 DERIVATIVE 25 OVG SET SPEED A 20 GAIN FACTOR note 1 20 SPEED FILTER note 2 16 STARTUP SPEED 1000 NOTE 1 Modify Gain Factor only if you run out of adjustment in a PID or OVG term NOTE 2 For the Speed Filter typically the value 24 works well on small 3 or 4 cylinder engines A value Tuning Methodology Once the engine is running the following procedure may be used to discover more optimum values for PID and the overall gain parameters OVG 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 Follow these steps 1 Set the integral and derivative terms to 0 2 Set the overall gain low lt
18. the PC the user must select a different parameter with the mouse pointer then reselect the value of Set Speed A The Woodward 8 Manual 36526F DPG 21XX 00X Digital Controllers Universal PST application also provides a Read All button that can be used to perform a complete refresh of all parameter values SET SPEED A is the controller s target speed after startup when Set Speed B is not selected The startup sequence is complete when the target speed and the engine speed reach the set speed The default value for SET SPEED A is 1000 MPU Hertz 25 Hertz ignition The SET SPEED A parameter s adjustable range extends from SET SPEED A MIN to SET SPEED A MAX DPG 2145 00X and DPG 2155 00X Models When a two position switch is connected between SET SPD 1 pin 12 and SET SPD 2 pin 6 then an open switch selects SET SPEED A as the controller s target speed If the controllers SET SPD inputs are not used then SET SPEED A is automatically the active target speed after the startup sequence is completed See the Installation Instructions chapter for details about using the speed select feature 3 3 Set Speed B optional DPG 2145 00X and DPG 2155 00X Models SET SPEED B becomes the controller s target speed when SET SPD 1 pin 12 and SET SPD 2 pin 6 of the connector are tied together In other words when a two position switch is connected between SET SPD 1 pin 12 and SET SPD 2 pin 6 then a closed switch selects SET SPEED B as
19. A selected when this pin is open To prevent damage to the controller make sure that it is wired in accordance with the wiring instructions and diagrams in this manual N O TI CE e Do not tin the leads before placing them into the terminals e Ensure the terminals are tightened properly to secure wires Woodward 31 Manual 36526F DPG 21XX 00X Digital Controllers Wiring Diagrams Cabling for DPG 21XX 00X controllers is limited to less than die TICE 30m 98 4 Power cabling is limited to less than 10m 32 8 in total length The wiring diagrams below show specific cable types required DPG 2101 00X Dimensions are in inches Dimensions in brackets are millimeters 1 SERIAL NO OH AG WOODWARD MPU SHIELD MPU Figure 1 Wiring Diagram for DPG 2101 001 and DPG 2101 002 Controllers Connect the MPU shield at the controller end only Connecting the shield at the MPU source end could introduce noise due to ground loops and also disable the reverse battery protection feature Woodward 32 Manual 36526F DPG 21XX 00X Digital Controllers DPG 2145 00X Dimensions are in inches Dimensions in brackets are millimeters PART NO DPG 2145 00X REV DEC SPEED INC SERIAL NO IN HNT HEIN WOODWARD SHLD act CL C ION GND BAT
20. AN woOopwAapn User Manual ERIALNO 3703 K 0001 TON ON A D IT d E PartNo DPG 2145 001 Ee RK l fe Si d DPG 2101 001 DPG 2145 001 DPG 21XX 00X Digital Controllers Programmable Controllers for Isochronous Generators Manual 36526F This is the safety alert symbol It is used to alert you to potential personal injury IMPOR TAN hazards Obey all safety messages that follow this symbol to avoid possible injury or death e DANGER Indicates a hazardous situation which if not avoided will result in death or serious injury DEFINITIONS e WARNING Indicates a hazardous situation which if not avoided could result in death or serious injury e CAUTION Indicates a hazardous situation which if not avoided could result in minor or moderate injury e NOTICE Indicates a hazard that could result in property damage only including damage to the control e IMPORTANT Designates an operating tip or maintenance suggestion The engine turbine or other type of prime mover should be equipped with an overspeed shutdown device to protect against runaway or damage to the prime mover with possible personal injury loss of life or property damage The overspeed shutdown device must be totally independent of the prime mover control system An overtemperature or overpressure shutdown device may also be needed for safety as appropriate Read this entire manual and all other publications pertaining to the work to be performe
21. Fuel limiting is achieved by setting the maximum duty cycle or on time allowed during one cycle of the PWM pulse width modulation signal controlling the actuator drive circuit The value assigned to the duty cycle limit parameter is a percentage and is limited to values in the range 10 to 95 The default value is 95 3 28 Startup Speed required The Startup Speed parameter should be set to an engine speed at least 10 higher than the fastest engine cranking speed but lower than the engine s idle speed This allows the controller to determine whether the engine is cranking or running whenever an engine speed signal is present See the Startup Sequence example in Chapter 5 If the Startup Speed value is set too low less than crank speed the controller s target speed will be ramped to the active set speed Idle Set Speed A or Set Speed B before the engine has started Therefore when the engine does start it may overspeed or output excessive smoke because the startup ramp having already completed no longer controls the rate of engine speed increase If the Startup Speed value is set too high above the active set speed then the Startup Speed becomes the target speed that the controller must reach before the it considers the startup sequence complete Typically the startup sequence ends when the engine speed reaches the active set speed The active set speed is the Idle Speed if the Idle Hold Time parameter is a nonzero value
22. Power and return cables to the control are routed together to minimize the noise pickup and emissions Similarly the power and return to the actuator must also be routed together but may be separated from the control s power leads 2 MOV and TVS suppression devices are recommended based on the typical pulse levels that might be seen in Group 1 or Group 2 engine applications and the internal circuitry of the control 3 Other suppression devices may be used but clamping voltages and energy handling capability are important as operating voltage and energy handling capability requirements depend on the full system implementation Examples a Two 15KP17CA and V47ZA7 through hole parts are available from Woodward as 8923 1272 KIT This kit is for a 24V system It will suppress alternator load dump from alternators within the 200A range as well as indirect lightning pulses that may be coupled to the power bus Parallel inductive loads still need to be suppressed because pulses from unsuppressed parallel loads will be clamped at voltages too high to protect the control b Two 15KP13CA and one V47ZA7 through hole parts are available from Woodward as 8923 1271 KIT This kit is for a 12V system with an alternator within the 100A range unsuppressed switched inductive loads in parallel with the control and indirect lightning pulses that may be coupled to the power bus 4 Suppression kits available from Woodward are intended to suppress th
23. _seconds startup_rate_value The ramp up will pause at the STARTUP SPEED until the controller senses an MPU signal greater than the STARTUP SPEED This prevents the startup ramp from reaching completion before the engine has even started The controller considers MPU frequencies below the STARTUP SPEED as indicating that the engine is cranking but has not yet started MPU frequencies above the STARTUP SPEED are taken to indicate that the engine has started and the controller will increase the engine speed until the selected set speed is reached Exception In cases where the target speed is less the STARTUP SPEED the startup ramp sequence ends when the target speed is reached When the NO of FLYWHEEL TEETH parameter is used the ACCEL RATE DECEL RATE and STARTUP RATE IM del R TA NT 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 3 17 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 pulse width modulated PWM duty cycle values do
24. alue is the minimum value allowed Universal PST not communicating with the controller Keypad failure replace unit Engine Does Not Start Actuator leads not connected or shorted No fuel source Turn on fuel source Battery voltage is low Charge or replace the battery 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 0 VRMS 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 Final target speed must be greater than crank speed before the controller will attempt to drive the actuator open Increase the Proportional value Engine Overspeeds at Startup Increase the appropriate Gain value Decrease the Startup Ramp Rate Woodward 38 Set speed is lower than crank speed Increase the set speed Manual 36526F DPG 21XX 00X Digital Controllers Troubleshooting Table Cont d SYMPTOM REMEDY Engine Does Not Reach Set Speed Improve PID tuning Integral too low or zero PID values are too low A tuning that is too soft can prevent the controller from delivering the needed actuator drive signal to reach the set speed PID values are too high Tuni
25. ance is also available during non business hours by phoning Woodward and stating the urgency of your problem Product Training is available as standard classes at many of our worldwide locations We also offer customized classes which can be tailored to your needs and can be held at one of our locations or at your site This training conducted by experienced personnel will assure that you will be able to maintain system reliability and availability Field Service engineering on site support is available depending on the product and location from many of our worldwide locations or from one of our Full Service Distributors The field engineers are experienced both on Woodward products as well as on much of the non Woodward equipment with which our products interface For information on these services please contact us via telephone email us or use our website and reference www woodward com support and then Customer Support How to Contact Woodward For assistance call one of the following Woodward facilities to obtain the address and phone number of the facility nearest your location where you will be able to get information and service Electrical Power Systems FACILITY PHONE NUMBER Brazil 55 19 3708 4800 China 86 512 6762 6727 Germany Kempen 49 0 21 52 14 51 Stuttgart 49 711 78954 0 India 91 129 4097100 Japan 81 43 213 2191 Korea
26. anufacturer s Name WOODWARD GOVERNOR COMPANY WGC Manufacturer s Address 1000 E Drake Rd Fort Collins CO USA 80525 Model Name s Number s DPG 2145 amp DPG 2155 Series Conformance to Directive s 2004 108 EC COUNCIL DIRECTIVE of 15 December 2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility and all applicable amendments Applicable Standards EN61000 6 4 2007 EMC Part 6 4 Generic Standards Emissions for Industrial Environments EN61000 6 2 2005 EMC Part 6 2 Generic Standards Immunity for Industrial Environments We the undersigned hereby declare that the equipment specified above conforms to the above Directive s Signature Karen Suhre Full Name Engineering Manager Position WGC Fort Collins CO USA Place 4 ZO Date 5 09 1183 Rev 15 22 Jan 2009 00327 04 EU 02 07 docx Woodward iii Manual 36526F DPG 21XX 00X Digital Controllers Declaration of Conformity DPG 2101 amp DPG 2146 DECLARATION OF CONFORMITY Manufacturer s Name WOODWARD GOVERNOR COMPANY WGC Manufacturer s Address 1000 E Drake Rd Fort Collins CO USA 80525 Model Name s Number s DPG 2133 DPG 2101 amp DPG 2146 Series Conformance to Directive s _2004 108 EC COUNCIL DIRECTIVE of 15 December 2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility and all applicable amendments Ap
27. ase for a DPG 2146 00X controller Note All Soeed and Rate values are shown as Hertz values parameters 2 4 14 16 20 22 25 26 Changing the value of parameter 1 will cause different default values to be displayed based on the Hertz to RPM formula Woodward Manual 36526F DPG 21XX 00X Digital Controllers DPG 2155 00X amp DPG 2145 00X Parameter List PARAMETER LIST FOR DPG 2155 00X MPU amp DPG 2145 00X IGNITION These controllers use the 12 terminal quick connect PARAMETER NAME DEFAULT MINIMUM MAXIMUM T 1 No of Flywheel 001 0 0 0 Ge E 0 0 572 Req 2 Set Speed A 1000 25 Set Speed A Min Set Speed A Max Opt 3 Set Speed B 1000 25 Set Speed B Min Set Speed B Max Opt 4 Idle Speed 50 20 Idle Speed Min Idle Speed Max Req 5 Proportional 25 1 99 Req 6 Integral 50 0 99 Req 7 Derivative 25 0 99 Req 8 OVG Set Speed A Use the controller s built in GAIN potentiometer Opt 9 OVG Set Speed B 20 1 99 Opt 10 OVG Idle Speed 20 1 99 Req 11 Gain Factor 20 40 1 99 Req 12 Speed Filter 16 4 1 24 Opt 13 Idle Hold Time 0 0 9999 Opt 14 Accel Rate 1000 3000 1 9999 Opt 15 Decel Rate 1000 3000 1 9999 Opt 16 Startup Rate 1000 3000 1 9999 Opt 17 Integral Low Limit 0 0 Integral High Limit Opt 18 Integral High Limit 99 Integral Low Limit 99 Opt 19 Passwor
28. ays to view engine speed data e The 0 to 12000 Hz option is the default and sets the vertical axis range to its absolute minimum and maximum measurable values e Thef to Hz option allows you to enter the minimum and maximum speed values to zoom in on a viewing range of interest e The 10 of Hz option is primarily used to zoom in on the target speed and center it in the chart recorder This is most useful during controller tuning to see if the engine speed stays within 10 of the target speed during load on off cycling The Horizontal Scale options allow you to set how much data is displayed in the chart recorder window Larger values compress the display and show more data Smaller numbers expand the display and show less data A Horizontal Scale setting of 20 seconds is approximately the same as a 5 millimeter per second paper travel speed of a conventional paper tape chart recorder The Chart Recorder Signal Filtering options can be used to smooth out noisy signals The default setting is Min which is no filtering Note that filtering will round out peaks and give a less accurate display of the speeds actually measured by the DPG Woodward 25 Manual 36526F DPG 21XX 00X Digital Controllers Engine Speed Data Collection The engine speed data measured by the DPG and displayed in the Universal PST chart recorder window is also recorded to a computer file MPU_DATA0O0 csv is the default file name used to save engin
29. cecde tens cabedsvardecsaes cbedisals bevbeyeabegesaeedevaee aeiia aaia 4 CHAPTER 3 PARAMETER REFERENCE scssseseeeeeseeneeeeessenneeeenseneenensseneeeennes 5 DPG 2101 00X A DPG 2146 00X Parameter lei 6 DPG 2155 00X A DPG 2145 00X Parameter lei 7 3 1 No of Flywheel Teeth or Pulses Per Revolution optional 8 3 2 Set Speed A reouired nesr ner nesr nernsernsrnnennssnnssnnnnns 8 3 3 Set Speed B Optional 22 2 0 ccc ceeececeeeeeceeeeeeeaeeeeneeeeeeesaeeeeaaesseneeesaees 9 3 4 Idle Speed optional 9 3 9 Proportional reQuIFEd vse ccvecteiens ecceteusescedes KNK AANKAN 10 3 6 Integral required sossen snanar EASKEN R EAA 10 3 7 Derivative required caieecsscticviectecocs ssaccevi encesesvenad tude essiesaasetinntenesierbeneiies 10 3 8 OVG Set Speed A required ceecceceeeeeeseeeeeeeeeeeeeeeeaeeeeeeeeeeeeeeees 11 3 9 OVG Set Speed B optional 11 3 10 OVG Idle Speed optional 11 3 11 Gain Factor required ccceeeeeecceceeeeeeeaeeeeeeeeeeeeeceaeeeeaaeseeaaeeseneeeaas 11 3 12 Speed Filter freouired A 11 3 13 Idle Hold Time Optional issons sanaaa 12 3 14 Accel Rate optional essiensa anena a AAKER EAE 12 3 15 Decel Rate optional sesiis uani EnaA ENNA AA 12 3 16 Startup Rate optional 13 3 17 Integral Low Limit optional 13 3 18 Integral High Limit optional 14 Be 1D PASSWOKC E 14 3 20 Over Speed Limit optional 14 3 21 Set Speed A Min optional 15 3 22 Set Speed A Max optional 15 3
30. d 0 0 99 Opt lt 20 Over Speed Limit o 1 Seier GE 1 Se EE Opt 21 Set Speed A Min 10 2 10 2 Set Speed A Opt 22 Set Speed A Max 11000 300 Set Speed A 11000 300 Opt 23 Set Speed B Min 10 2 10 2 Set Speed A Opt 24 Set Speed B Max 11000 300 Set Speed B 11000 300 Opt 25 Idle Speed Min 10 2 10 2 Idle Speed Opt 26 Idle Speed Max 11000 300 Idle Speed 11000 300 Opt 27 Duty Cycle Limit 95 10 95 Req 28 Startup Speed 1000 25 10 2 11000 300 Opt 29 Startup Duty Cycle 30 5 95 Req Parameter adjustment required to achieve Basic Governing Opt Parameter use is optional Default Minimum and Maximum values in parenthesis apply when the controller uses ignition pulses to sense engine speed which would be the case for a DPG 2145 00X controller Note All Soeed and Rate values are shown as Hertz values parameters 2 4 14 16 20 26 Changing the value of parameter 1 will cause different default values to be displayed based on the Hertz to RPM formula Woodward Manual 36526F DPG 21XX 00X Digital Controllers 3 1 No of Flywheel Teeth or Pulses Per Revolution optional This parameter provides the conversion factor needed to display speeds as RPM values instead of Hertz values Adjusting this parameter is optional The default value of 0 disables Hertz Hz to RPM conversions so all set speeds are displayed in Hertz Setting this parameter to a value other than zero enables Hertz to RPM
31. d before installing operating or servicing this equipment Practice all plant and safety instructions and precautions Failure to follow instructions can cause personal injury and or property damage This publication may have been revised or updated since this copy was produced To verify that you have the latest revision be sure to check the Woodward website www woodward com pubs current pdf The revision level is shown at the bottom of the front cover after the publication number The latest version of most publications is available at www woodward com publications If your publication is not there please contact your customer service representative to get the latest copy Any unauthorized modifications to or use of this equipment outside its specified mechanical electrical or other operating limits may cause personal injury and or property damage including damage to the equipment Any such unauthorized modifications i constitute misuse and or negligence within the meaning of the product warranty thereby excluding warranty coverage for any resulting damage and ii invalidate product certifications or listings To prevent damage to a control system that uses an alternator or battery charging N e TI C E device make sure the charging device is turned off before disconnecting the battery from the system To prevent damage to electronic components caused by improper handling read N e TI C E and observe the precautions in W
32. dit for the core charge will be issued Flat Rate Repair Flat Rate Repair is available for the majority of standard products in the field This program offers you repair service for your products with the advantage of knowing in advance what the cost will be All repair work carries the standard Woodward service warranty Woodward Product and Service Warranty 5 01 1205 on replaced parts and labor Flat Rate Remanufacture Flat Rate Remanufacture is very similar to the Flat Rate Repair option with the exception that the unit will be returned to you in like new condition and carry with it the full standard Woodward product warranty Woodward Product and Service Warranty 5 01 1205 This option is applicable to mechanical products only Woodward 41 Manual 36526F DPG 21XX 00X Digital Controllers Returning Equipment for Repair If a control or any part of an electronic control is to be returned for repair please contact your Full Service Distributor in advance to obtain Return Authorization and shipping instructions When shipping the item s attach a tag with the following information return number name and location where the control is installed name and phone number of contact person complete Woodward part number s and serial number s description of the problem instructions describing the desired type of repair Packing a Control Use the following materials when returning a complete control protective caps on
33. e 30 View Chart Universal PST Version 3 0 0 E File Weu Port Help Vertical Scale Hert Horizontal Scale in seconds 3 Oto 12000 Hz a Ceo 306 201005 Tuning View C o mmieoo Hz S SS 0 0 Chart Recorder Signal Filtering C t 10 0f 1000 He Min O COCCOCC Max Name_ Value Proportional 40 Integral 50 Derivative 25 OVG Set Speed A 20 OVG SetSpeedB 20 OVG Idle Speed 20 Gain Factor 20 Speed Filter 16 Startup Limit 1000 Torque Limit 1000 Integral Low 0 Integral High 99 Data File C5 Woodwardsapps Universal PST v3 MPU_DA ENEE A V gt Data Reset View Table WOODWARD OKO In Chart View the user can e Monitor engine speed in real time e Adjust the horizontal and vertical scale settings of the chart recorder e Edit parameter values related to controller tuning These same parameters are also on the main parameter setup table e Press the lt Data File gt button to open a file for saving chart recorder data e Press the lt Data Reset gt button to start data collection to the open file at the beginning e Press the lt Pause Chart gt button to stop the chart recorder which also stops writing data to the file Press the lt Continue gt button to turn the chart recorder back on e Press the lt View Table gt button to set the display mode back to Table View e Select items from the menu Data File
34. e 9 30 Vdc 2 ACT Actuator drive output 3 Not Labeled Digital input common 4 INC Digital input to increase selected set speed Active when tied to Pin 3 5 IGN TACH Ignition tachometer signal input 6 SET SPD 2 Ge SE B selected when this pin tied to 7 BAT Battery negative 8 ACT Actuator drive return 9 SHIELD Ground connection for cable shielding 10 DEC Digital input to decrease selected set speed Active when tied to Pin 3 11 IGN GND Ignition ground signal 12 SET SPD 1 Set Speed A selected when this pin is open Woodward 30 Manual 36526F DPG 21XX 00X Digital Controllers DPG 2146 00X NO NAME FUNCTION 1 BAT Battery positive 9 30 Vdc 2 BAT Battery negative 3 ACT Actuator drive output 4 ACT Actuator drive return 5 IGN TACH Ignition tachometer signal input 6 IGN GND Ignition ground signal 7 SHIELD Ground connection for cable shielding DPG 2155 00X NO NAME FUNCTION 1 BAT Battery positive 9 30 Vdc 2 ACT Actuator drive output 3 Not Labeled Digital input common 4 INC Digital input to increase selected set speed Active when tied to Pin 3 5 MPU Magnetic pickup signal inputs 6 SET SPD 2 SES B selected when this pin tied to 7 BAT Battery negative 8 ACT Actuator drive return 9 SHIELD Ground connection for cable shielding 10 DEC Digital input to decrease selected set speed Active when tied to Pin 3 11 MPU Magnetic pickup ground 12 SET SPD 1 Set Speed
35. e majority of the likely pulses However they will not protect against all system level implementations outside the intended usage of the control A system level evaluation of what pulses may be present should be undertaken Please see Application Note 51319 for more details Woodward 37 Manual 36526F DPG 21XX 00X Digital Controllers Chapter 7 Diagnostics amp Troubleshooting ee a LED Indications LED STATE MEANING Controller is either not currently powered or is being reverse Off powered Check polarity of supplied power If correctly powered then controller is malfunctioning Blinking Slow Controller is powered but not sensing a speed signal OK if 1 2 Hz engine is not running If the engine is running then this indicates a fault with the speed signal inki Controller is powered and an engine speed signal is being Bink ng Fast detected H the engine is not running then this indicates 1 Hz e S electrical noise on the speed signal wires ON and Not i Su Blinking Controller is powered and is malfunctioning Replace controller Troubleshooting Table SYMPTOM REMEDY Powered LED Display Does Not Light BAT and BAT leads are reversed Check wiring Up When Controller Is Battery voltage too low Should measure between 9 30 Vdc Controller is defective Replace it Unable to Modify Parameters The parameter s value is the maximum value allowed The parameter s v
36. e controller is not seeing a speed signal This means the engine is not running If the engine is running or cranking and the LED is blinking slow then refer to the troubleshooting chapter for help in diagnosing why the speed signal to the controller is missing A fast blinking LED indicates all of the following 1 The unit is powered 2 There is an engine speed signal at the controller s tachometer inputs When the LED is on and not blinking it indicates the following 1 The unit is powered 2 There is a controller fault NOTE The slow blink rate 1 2 Hertz the LED is turned on for 1 second followed by off for 1 second then on again and so on The fast blink rate is 3 times faster than the slow blink rate COMM Port All adjustments may be done by having the controller connected via the COMM port to a computer running the Universal PST application Remote access via the COMM port is intended for connection only while programming tuning and troubleshooting the control It is a service port and not intended for permanent connection The Universal PST is an MS Windows based application available from the Software Products page at www woodward com IC Software See Chapter 4 for a description of this tool The COMM port is intended only for configuration and N el T Le E periodic service Do not leave a computer and or COMM cable connected to the COMM port Woodward 4 Manual 36526F DPG 21XX 00X Digital Controllers
37. e speed information You can change the file name by using the lt Data File gt button The csv data files created to collect engine speed data can be viewed with either a text editor or with Microsoft Excel H you load an engine speed data file into Microsoft Excel then you can highlight the column of data and use Excel s quick graph button to create a line chart of the data IMPORTANT Do not open data files in another program that are currently being used by Universal PST Also be sure to close any open data files needed by Universal PST before starting it Data File Cream Files Woodward Universal PST MPU_ Pause Chart Data Reset View Table The lt Data File gt button opens a dialog box allowing you to set the base file name where chart recorder data will be saved A two digit suffix is automatically appended to the file name that is given and serves the following purpose Each engine speed data file is considered full after recording 60 000 data points which is approximately 10 12 minutes of data The two digit suffix is used to automatically continue collecting data to new files with the same base file name but with increasing numeric suffixes The first 60 000 data points are saved in filename00 csv and the next 60 000 data point are saved in filename01 csv and so on until a million data points are collected This is to prevent each speed data file from exceeding the 65 536 row limit of Microsoft Excel The lt Data Res
38. er 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 over_speed_limit_value 100 highest_set_speed Woodward 14 Manual 36526F DPG 21XX 00X Digital Controllers DPG 21XX 002 Models This parameter is used to determine the engine speed that will trigger the controller to output minimum fuel The parameter s value is set as a frequency in Hertz or as a RPM value depending on whether the No of Flywheel Teeth parameter is zero or nonzero respectively The default value of 15 000 Hertz 450 Hertz ignition is used to disable over speed detection The controller detects an over speed condition when it measures an engine speed that exceeds the OVER SPEED LIMIT value When an over speed is detected the controller s actuator output signal is set to minimum N el E The controller must be turned off to clear the over speed detection before the engine can be restarted 3 21 Set Speed A Min optional Set Speed A Min is used to set the lowest value allowed for Set Speed A adjustments The adjustable range for Set Speed A Min extends from 10 Hertz 2 Hertz ignition to the current value of Set Speed A 3 22 Set Speed A Max optional Set Speed A Max is used to set the hi
39. et gt button is used to clear out the data collection buffer and overwrite the zero suffixed data collection file Data collection starts from the beginning of filename00 txt where filename is the base file name previously used The progress bar shown to the right of the lt Data Reset gt button indicates how full the complete set of data files is A total of one million data points approximately 3 5 hours of data can be collected before the progress bar displays the message The Data File is FULL In order to start recording data again without overwriting previously collected data use the lt Data File gt button to create a new base file name in which to receive additional engine speed information The lt Pause Chart gt button stops chart recorder and Data File updates After pressing this button the lt Continue gt button is displayed Press the lt Continue gt button to turn the chart recorder back on and continue recording engine speed data to the current target file Use the lt View Table gt button to return to the Table View display mode Be sure to open a new Data File before returning to Table View if the data already collected needs to be saved The active data file is automatically reset each time the Chart View display mode becomes active Woodward 26 Manual 36526F DPG 21XX 00X Digital Controllers Chapter 5 Calibration Instructions Basic Adjustments The controller is programmed at the factory with default
40. f Flywheel 001 0 0 0 Opt Teeth or Pulses per revolution 002 0 0 572 Req 2 Set Speed A 1000 25 Set Speed A Min Set Speed A Max 3 Not Available Opt 4 Idle Speed 50 20 Idle Speed Min Idle Speed Max Req 5 Proportional 25 1 99 Req 6 Integral 50 0 99 Req 7 Derivative 25 0 99 Req 8 OVG Set Speed A Use the controller s built in GAIN potentiometer 9 Not Available Opt 10 OVG Idle Speed 20 1 99 Req 11 Gain Factor 20 40 1 99 Req 12 Speed Filter 16 4 1 24 Opt 13 Idle Hold Time 0 0 9999 Opt 14 Accel Rate 1000 3000 1 9999 Opt 15 Decel Rate 1000 3000 1 9999 Opt 16 Startup Rate 1000 3000 1 9999 Opt 17 Integral Low Limit 0 0 Integral High Limit Opt 18 Integral High Limit 99 Integral Low Limit 99 Opt 19 Password 0 0 99 OP 20 Over Speed Limit 02 1 000 Zen o 1 5000 Zen Opt 21 Set Speed A Min 10 2 10 2 Set Speed A Opt 22 Set Speed A Max 11000 300 Set Speed A 11000 300 23 Not Available 24 Not Available Opt 25 Idle Speed Min 10 2 10 2 Idle Speed Opt 26 Idle Speed Max 11000 300 Idle Speed 11000 300 Opt 27 Duty Cycle Limit 95 10 95 Req 28 Startup Speed 1000 25 10 2 11000 300 Opt 29 Startup Duty Cycle 30 5 95 Req Parameter adjustment required to achieve Basic Governing Opt Parameter use is optional Default Minimum and Maximum values in parenthesis apply when the controller uses ignition pulses to sense engine speed which would be the c
41. gains are provided for tailoring controller response to many engine applications Other adjustments include acceleration and deceleration ramp rates idle speed set hold time and more Properly tuned this controller delivers fast engine response to speed or load change while providing precise stable isochronous operation The controller s internal FAILSAFE reacts instantly to loss of the engine speed signal allowing the actuator to return to minimum fuel Features include e lsochronous speed control e User friendly operator adjustable e Precision frequency control e Superior temperature stability e Reverse battery protection e Input voltage range 9 30 Vdc e Remote setup e Serial communication port Actuator Compatibility DYNA 2000 DYNA 7000 DYNA 8000 APECS 0150 DYNA 2500 DYNA 70025 DYNA 8200 APECS 0250 DYNA 10141 DYNA 8400 APECS 0300 APECS Linkage Free Integral Type Other Models Available DPG 2100 Series for Genset Applications DPG 2300 Series for Off Road Vehicles DPG 2400 Series for EFC Valve Applications Woodward 1 Manual 36526F DPG 21XX 00X Digital Controllers Chapter 2 Controller Specifications The controller s main electrical and mechanical specifications are listed here along with several performance characteristics DPG 21XX 00X Series controllers are available in five hardware configurations Configurations Connector Style Speed Sensing
42. ge 2 Hertz to 350 Hertz Governing Speed Range with Ignition 25 Hertz to 300 Hertz Suggested Mating Connectors for DPG 2145 00X and DPG 2155 00X Models AMP 770581 1 Mini universal Mate N Lock AMP 171637 3 or 794407 3 Duplex finish socket AMP 90707 1 Crimping hand tool for 18 gauge wire AMP 408 4137 Crimping documentation AMP 189727 1 Socket extraction tool Keypad User Interface Operation The DPG 21XX 00X provides two buttons for adjusting the engine set speed e INC increases the selected Set Speed A or B e DEC decreases the selected Set Speed A or B Gain Potentiometer The DPG 21XX 00X series controllers provide a potentiometer labeled GAIN to adjust the OVG Set Speed A This is one of the controller s tuning parameters The gain potentiometer s adjustment range is 1 to 99 LED The LED Light Emitting Diode is used as a status indicator When the LED is off it indicates that one of the following is true e The unit is not being powered e The unit is reverse powered check polarity of supplied power If a voltage between 9 Vdc and 30 Vdc is being properly supplied across the BAT and BAT connector pins of the controller and the LED is off then refer to the troubleshooting chapter A slow blinking LED indicates all of the following Woodward 3 Manual 36526F DPG 21XX 00X Digital Controllers 1 The unit is powered 2 Th
43. ghest value allowed for Set Speed A adjustments The adjustable range for Set Speed A Max extends from the current value of Set Speed A to 11000 Hertz 300 Hertz ignition 3 23 Set Speed B Min optional DPG 2145 00X and DPG 2155 00X Models Set Speed B Min is used to set the lowest value allowed for Set Speed B adjustments The adjustable range for Set Speed B Min extends from 10 Hertz 2 Hertz ignition to the current value of Set Speed B 3 24 Set Speed B Max optional DPG 2145 00X and DPG 2155 00X Models Set Speed B Max is used to set the highest value allowed for Set Speed B adjustments The adjustable range for Set Speed B Max extends from the current value of Set Speed B to 11000 Hertz 300Hertz ignition 3 25 Idle Speed Min optional Idle Speed Min is used to set the lowest value allowed for Idle Speed adjustments The adjustable range for Idle Speed Min extends from 10 Hertz 2 Hertz ignition to the current value of Idle Speed 3 26 Idle Speed Max optional Idle Speed Max is used to set the highest value allowed for Idle Speed adjustments The adjustable range for Idle Speed Max extends from the current value of Idle Speed to 11000 Hertz 300Hertz ignition Woodward 15 Manual 36526F DPG 21XX 00X Digital Controllers 3 27 Duty Cycle Limit optional The Duty Cycle Limit 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
44. he Universal PST Help menu Synchronizing Universal PST with a DPG Pressing the lt Read All gt button will load the current values for all of a DPG 2XXX 00X s parameters into Universal PST The lt Read All gt button is part of the Table View IMPORTANT If the communication cable is unplugged from a DPG and plugged into a different DPG while the Universal PST application is still running then the lt Read All gt button must be pressed in order for Universal PST to synchronize with the new DPG The lt Write All gt button is very useful when reusing saved setup data to configure a new system with the same data as a previous one Simply load an existing set of previously saved parameter values into the Parameter Setup table using Open a setup data file from the File menu then press the lt Write All gt button Status View The Status View panel is displayed only after pressing Status View the lt View Status gt button The Status View panel is part a EE of the Table View display mode remem Battery Volts The Status View panel displays a table where each row ees shows the Name of a read only parameter and its current Digital Inputs Value when Auto Read is ON a Press left mouse click the lt START Monitoring gt button to have the Universal PST program automatically refresh the Values Press the lt STOP Monitoring gt button to disable automatic refresh START Monitoring Auto Read is OFF i Woodward 24
45. ine s speed when a new lower target speed is made active The parameter value is specified in Hertz per second based on the following formula higher_speed_in_Hertz lower_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 controller 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 Woodward 12 Manual 36526F DPG 21XX 00X Digital Controllers 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 5 463 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 startup rate specifies how fast the controller 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
46. llation program will detect operating system components older than those required by the Universal PST application In this case the installation program will ask if you want to update Windows If you do not want setup to update your system then you can not use the Universal PST application on this computer Read the setup program s instructions carefully as they appear and respond as needed The installation may take as long as 7 minutes depending on your computer s power and operating system Do not interrupt the installation program even though it may appear as though it is not running NOTE Administrator rights may be needed to install on some Microsoft Windows operating systems such as Windows XP Professional for the setup program to properly register application resources Wiring the COMM Port to a PC To construct a communications cable to use between the DPG s COMM port and your PC s RS 232 serial port refer to the table and wiring diagram below RJ11 OR RJ12 S POSITION DPG 21XX SIGNAL CONNECTS TO 1 No connection N C PC receive RxD 2 Transmit data to PC l DB9 pin 2 PC transmit TxD 3 Receive data from PC Ve DB9 pin 3 PC common 4 COMMON DB9 pin 5 5 5 Vdc Do NOT NIC connect at the PC end 6 No connection N C Remote access via the COMM port is intended for NO TICE connection only while programming tuning and troubleshooting the control engine It is a service p
47. looks suspicious or you do not fully trust the source do not open or save this file File name UniversalPST_NEW exe File type Application From www woodward com A This type of file could harm your computer if it contains malicious code Would you like to open the file or save it to your computer Open E E Cancel More Info V Always ask before opening this type of file NOTE Due to the large file size it is recommended that the Open button not be used because this would try to run the self extracting executable from the web site Woodward 19 Manual 36526F DPG 21XX 00X Digital Controllers Installing Universal PST Instructions to Install from CD ROM When you insert the DPG Software Calibration Kit s CD ROM into your computer the autorun file on the CD will attempt to launch the setup exe program If the autorun feature is disabled on your computer or does not start the setup program you can launch the program manually To start the installation manually explore the contents of the CD then double click on the setup exe file Instructions to Install from the Downloaded File The file downloaded from the Woodward web site contains two files ReadMeFirst txt and setup exe Run the downloaded file to extract its contents to a folder you choose on your computer s hard drive Then run the setup exe program from the folder you extracted it to IMPORTANT The insta
48. ng is too hot or oversensitive to small speed errors which causes the controller to make large rapid changes in actuator drive signal creating 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 Engine Takes Too Long to Reach the Set Speed 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 Engine Does Not Track Speed Setting Changes Is the LED blinking fast 3 Hz No not sensing speed Is the selected set speed parameter being modified A PID value or a Gain value is too high A PID value is too low or zero Accel Rate is set too low Decel Rate is set too low Sluggish Response to Load Changes Gain too low Improve PID tuning Speed filter setting is too high Engine Instability With No Load Improve PID tuning Speed filter setting is too low Fuel is restricted Check actuator linkage Battery voltage is too low Engine Instability With Load Improve PID tuning Fuel is restricted Check actuator linkage Battery voltage is too low Engine Unable to Carry Rated Load PID values may be too high causing the controller to overreact and make large rapid changes in PWM duty cycle output to the actuator Imp
49. omatic configuration to each DPG when communications are established e Read write access to all DPG programmable parameters and features e View each parameter s default minimum and maximum values e Diagnostics utilizing automatic refresh of DPG status e Save and open DPG setup data information to and from a file for reuse e Single button read to get the current values of all parameters e Single button write to program a DPG with previously saved setup values e Engine speed monitoring via a chart recorder to aid in tuning the controller e Saving chart recorder data to a Microsoft Excel compatible file e Help information on each of the controller s parameters e Help information on using the Universal PST System Requirements Universal PST minimum system requirements e Pentium 133 MHz PC e 50 MB of hard disk space e 64 MB of RAM e Display resolution set to SVGA 800x600 or higher e Windows 98se NT 4 0 2000 and XP or greater e Windows 95 or ME not supported An unsafe condition could occur with improper use of these software tools Only trained personnel should have access to these tools Woodward 18 Manual 36526F DPG 21XX 00X Digital Controllers Acquiring Universal PST There are two ways to acquire a copy of the Universal PST application e Obtain the DPG Software Calibration Kit e Download the application from the Woodward website Obtaining the DPG Software Calibration Kit The DPG Software Calibration Ki
50. ontroller output response to a step change in the speed error Saturation a lower Proportional value Decreases output response to a step Change in error Proportional response SZ ES Q 8 et CO by re c e O Saturation e D e Error Each error value produces a unique controller output value 3 6 Integral required The integral term is one of Integral response to constant error the interrelated PID terms that determine how well a DPG controller governs the engine s speed The integral term acts to drive speed error to zero 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 term is key to isochronous speed control This term eliminates the difference between the programmed set speed and the actual speed The integral gain changes the time it takes to drive the error to zero arger Integral value smaller Integral value Controller output Note Integral is needed to eliminate speed offsets due to proportional gain and should never be left at zero 3 7 Derivative required Derivative response to EH in the rate of deceleration or the The derivative term is one of the rate EH acceleration interrelated PID terms that determine how well a DPG controller governs the engine s speed The derivative responds to the rate of change in the speed error This
51. oodward manual 82715 Guide for Handling and Protection of Electronic Controls Printed Circuit Boards and Modules f Revisions Text changes are indicated by a black line alongside the text Woodward Governor Company reserves the right to update any portion of this publication at any time Information provided by Woodward Governor Company is believed to be correct and reliable However no responsibility is assumed by Woodward Governor Company unless otherwise expressly undertaken Woodward 2009 All Rights Reserved Manual 36526F DPG 21XX 00X Digital Controllers Contents EE REGULATORY COMPLIANCE sssssiaiessnnseneavanisunsxavaieniannchutdnancantinensansesennareiuied Ill Declaration of Conformity DPG 2145 amp DPG 21Db eeecceeeeeeeteeeteeeeeneeteneeeees iii Declaration of Conformity DPG 2101 amp DPG 2148 iv EMG Limitations euer Nee EES EEdeEEEEE SE eg v ELECTROSTATIC DISCHARGE AWARENESS ssseecessesteeeeneeneneenseneeneeneenes vi CHAPTER 1 GENERAL INFORMATION ccccsssesteeeeseeneeeesseneeeeenseneeeeenesnnenennes 1 latgrelet Leen ee 1 CHAPTER 2 CONTROLLER SPECIFICATIONS cccccsseseeeeesseneeeesseseeneeseeneenennes 2 elt Ms e EE 2 See 2 Mecnamgal ssoi enee based a aA a E A 2 Porman EE 3 User Interface Operation sscsisisinionriiniiianiinnnriasnandianaatan aeaa aasia naiai 3 e E 3 E BE Ee Tu TEE 3 ED ee dei cate einen des aea deet ebe Fe gacsay davavaet Seine adda steleseadte Ree Set 3 COMM POf sce cicscccep este c
52. or the selected set speed either Set Speed A or Set Speed B To determine the proper value for this parameter the crank speed must be known There are two ways to determine the engine crank speed 1 Use ameter to measure the frequency across the MPU and MPU terminals of the controller during cranking or 2 Use aPC running the Universal PST application and read the value of the Measured Speed in the View Status panel when the engine is cranking Note From the Universal PST startup screen press the View Status button then press the Start Monitoring button to begin reading values 3 29 Startup Duty Cycle optional The Startup Duty Cycle parameter is used to pre load the PID output with a PWM duty cycle value close to that needed for the actuator to allow enough fuel to idle the engine If the value is too low then the engine crank time may be longer than desired because the controller s actuator output starts from a value much smaller than needed to begin opening the fuel valve If the value is too high then the engine may overspeed because the actuator opens more than needed to start the engine There are two ways to determine a good value to use for this parameter 1 Use ameter to measure the duty cycle across the ACT terminals of the controller while the engine is running Note To determine if your meter is reading the correct value Woodward 16 Manual 36526F DPG 21XX 00X Digital Controllers 2 a Fir
53. ort and not intended for permanent connection of a PC and or cable Woodward 20 Manual 36526F DPG 21XX 00X Digital Controllers Communications Error The following message window appears when Universal PST is running and unable to communicate with a DPG Communications Error Is the serial cable connected Is the serial cable wired correctly Is the correct COMM Port selected Is the DPG powered After the problem is found and corrected you can either restart Universal PST or press the lt Read All gt button to clear the error message The lt Read All gt button is near the lower left corner of Universal PST s main startup screen Universal PST User Interface Overview Universal PST has two main display modes e Table View the main startup screen e Chart View TABLE VIEW Universal PST Version 3 0 0 Ele View Port Help Function Code 0 DPG 2201 Parameter Setup SE Name _Value_ Default Minimum Maximum Name _Value_ Default Minimum Maximum 1 Number of Teeth D 0 D 0 21 Percent Droop D 0 D 100 2 Set SpeedA 1000 1000 10 11000 22 No Load Cal 0 H 0 1000 3 Set Speed B 1000 100 18 11000 23 Full Load Cal 4 Idle Speed 500 500 10 11000 24 Password 5 Proportional mm 8 1 99 25 Over Speed Limit 6 Integral 50 a 0 99 26 Set Speed A Min 7 Derivative 3 5 0 99 27 Set Speed A Max 8 OVG Set SpeedA 20 20 1 99 28 Set Speed B Min 9 ONG Set SpeedB 20 20 1 99 29
54. overload situation causes the engine speed to remain below the target speed for some period of time then the integral portion of PID output would grow larger than otherwise needed would windup Therefore 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 Use carefully as improper use can prevent the controller N e TI C E from ever reaching the target speed The first line of defense in reducing over speed or under speed errors is a well tuned controller via the PID terms 3 19 Password The Password parameter is not available on DPG 21XX 00X Series models 3 20 Over Speed Limit optional DPG 21XX 001 Models This parameter is used to determine the engine speed that will trigger the controller 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 paramet
55. parameter is primarily used to dampen very rapid oscillations resulting from large speed changes The derivative responds to engine acceleration or deceleration If the engine speed approaches the target speed at a fast rate the derivative acts Controller output Ge Se Th led at lar int I to minimize or eliminate overshoot A The error is sampled at regular intervals _ zero value is allowed but systems When the Rate of change changes red dot the typically require some derivative gain to Derivative s impact on controller output changes improve overall engine speed control Woodward 10 Manual 36526F DPG 21XX 00X Digital Controllers 3 8 OVG Set Speed A required This overall gain acts as the multiplier on the three PID terms proportional integral derivative when Set Speed A is selected as the active target speed The controller s built in gain potentiometer is adjustable from 1 to 99 3 9 OVG Set Speed B optional DPG 2145 00X and DPG 2155 00X Models This overall gain acts as the multiplier on the three PID terms proportional integral derivative when Set Speed B is selected as the active target speed This overall gain term is adjustable from 01 to 99 3 10 OVG Idle Speed optional This overall 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 start
56. plicable Standards EN61000 6 4 2007 EMC Part 6 4 Generic Standards Emissions for Industrial Environments EN61000 6 2 2005 EMC Part 6 2 Generic Standards Immunity for Industrial Environments We the undersigned hereby declare that the equipment specified above conforms to the above Directive s ANUFACTURER Signature Karen Suhre Full Name Engineering Manager Position WGC Fort Collins CO USA Place 297 o 5 09 1183 Rev 15 22 Jan 2009 00327 04 EU 02 04 doc Woodward iv Manual 36526F DPG 21XX 00X Digital Controllers EMC Limitations Cabling All cabling for this unit is limited to less than 30m 98 4 See wiring diagrams for specific cable types required Power cabling is limited to less than 10m 32 8 in total length from its source power is intended to be from a local bus structure The control is NOT intended to have a power bus that is derived from a plant wide distribution system remote source or similar mains type distribution systems The power to the control should also be a dedicated circuit directly to the battery or source via a power and return wire that are routed together See User Manual 36526 for additional regulatory information limitations and wiring diagrams with specific required cable types Power Bus The power bus is intended to be a local bus without power line surges and to have inductive load kickback events suppressed Therefore
57. qual to 500 Hertz per second The example also has SET SPEED A set at 3500 Hertz so it will take 4 seconds for the target speed to ramp up 2000 Hertz from the IDLE SPEED Ramping stops at point E when the target speed reaches SET SPEED A The startup sequence also ends at point E assuming the engine speed has been tracking the target speed and has reached SET SPEED A Woodward 29 Manual 36526F DPG 21XX 00X Digital Controllers Chapter 6 Installation Instructions Recommended Mounting The DPG 21XX 00X controller is designed to be panel mounted and its chassis electrically bonded to the same protective reference as the engine structure The mounting location should protect the controller from exposure to rain weather and direct sunlight The controller should not be mounted on the engine or in an environment that exceeds the mechanical specifications outlined in Chapter 2 of this manual The controller should be mounted in a position to allow access to the user interface the COMM port and the terminal strip Terminal Descriptions DPG 2101 00X NO NAME FUNCTION 1 BAT Battery positive 9 30 Vdc 2 BAT Battery negative 3 ACT Actuator drive output 4 ACT Actuator drive return 5 MPU Magnetic pickup signal input 6 MPU Magnetic pickup ground 7 SHIELD Ground connection for cable shielding DPG 2145 00X NO NAME FUNCTION 1 BAT Battery positiv
58. r or the OEM or Packager of the equipment system based on the standard Woodward Product and Service Warranty 5 01 1205 that is in effect at the time the product is originally shipped from Woodward or a service is performed e Replacement Exchange 24 hour service e Flat Rate Repair e Flat Rate Remanufacture Replacement Exchange Replacement Exchange is a premium program designed for the user who is in need of immediate service It allows you to request and receive a like new replacement unit in minimum time usually within 24 hours of the request providing a suitable unit is available at the time of the request thereby minimizing costly downtime This is a flat rate program and includes the full standard Woodward product warranty Woodward Product and Service Warranty 5 01 1205 This option allows you to call your Full Service Distributor in the event of an unexpected outage or in advance of a scheduled outage to request a replacement control unit If the unit is available at the time of the call it can usually be shipped out within 24 hours You replace your field control unit with the like new replacement and return the field unit to the Full Service Distributor Charges for the Replacement Exchange service are based on a flat rate plus shipping expenses You are invoiced the flat rate replacement exchange charge plus a core charge at the time the replacement unit is shipped If the core field unit is returned within 60 days a cre
59. rove PID tuning Fuel is restricted Check actuator linkage Woodward 39 Manual 36526F DPG 21XX 00X Digital Controllers Chapter 8 Service Options EE Product Service Options If you are experiencing problems with the installation or unsatisfactory performance of a Woodward product the following options are available Consult the troubleshooting guide in the manual Contact the manufacturer or packager of your system Contact the Woodward Full Service Distributor serving your area Contact Woodward technical assistance see How to Contact Woodward later in this chapter and discuss your problem In many cases your problem can be resolved over the phone If not you can select which course of action to pursue based on the available services listed in this chapter OEM and Packager Support Many Woodward controls and control devices are installed into the equipment system and programmed by an Original Equipment Manufacturer OEM or Equipment Packager at their factory In some cases the programming is password protected by the OEM or packager and they are the best source for product service and support Warranty service for Woodward products shipped with an equipment system should also be handled through the OEM or Packager Please review your equipment system documentation for details Woodward Business Partner Support Woodward works with and supports a global network of independent business partners whose mis
60. s e Do not touch any part of the PCB except the edges e Do not touch the electrical conductors the connectors or the components with conductive devices or with your hands e When replacing a PCB keep the new PCB in the plastic anti static protective bag it comes in until you are ready to install it Immediately after removing the old PCB from the control cabinet place it in the anti static protective bag To prevent damage to electronic components caused by improper handling read and observe the precautions in N e TI C E Woodward manual 82715 Guide for Handling and Protection of Electronic Controls Printed Circuit Boards and Modules Woodward vi Manual 36526F DPG 21XX 00X Digital Controllers Chapter 1 General Information El Introduction This manual provides information on the following DPG controllers DPG 2101 001 and DPG 2145 001 and DPG 2155 001 and DPG 2101 002 DPG 2145 002 DPG 2155 002 DPG 2146 001 and DPG 2146 002 The DPG 21XX 00X digital controller 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 set speed and gain parameters with the built in user interface The COMM port provides access to all other controller settings allowing adaptation to each application during service and initial configuration Separately programmable Proportional Integral and Derivative
61. s before placing them into the terminals Ensure the terminals are tightened properly to secure wires Woodward 35 Manual 36526F DPG 21XX 00X Digital Controllers Centralized Suppression The control meets the regulatory requirements for its intended installations and when installed correctly as directed the DPG input power can handle some level of surge pulses Because the control power input is designed to be connected to a local bus and to have inductive load kickbacks suppressed it cannot withstand a charging system load dump heavy inductive kickbacks or heavy surge pulses 1 Charging system load dump is a pulse created when a heavily charging battery that is being charged by an alternator or generator or similar is disconnected from the bus 2 Inductive kickbacks are due to series or parallel switched unsuppressed inductive loads switched ON and OFF wired on the same power bus 3 Large surge pulses are typically due to indirect lightning strikes Some surge pulses may also be present due to series inductances with switched currents The EMC environment into which the control is installed may have the above conditions if the control is installed OUTSIDE its intended usage If the stated conditions exist centralized pulse suppression should be implemented to protect the components on the bus including the control Figure 2 is an example of centralized suppression that should be implemented at the system level
62. sients and transmitter signals coupled into the communication cable Cable orientation and short cable length may be used to eliminate these issues depending on the severity of the environment Woodward V Manual 36526F DPG 21XX 00X Digital Controllers Electrostatic Discharge Awareness All electronic equipment is static sensitive some components more than others To protect these components from static damage you must take special precautions to minimize or eliminate electrostatic discharges Follow these precautions when working with or near the control 1 Before doing maintenance on the electronic control discharge the static electricity on your body to ground by touching and holding a grounded metal object pipes cabinets equipment etc 2 Avoid the build up of static electricity on your body by not wearing clothing made of synthetic materials Wear cotton or cotton blend materials as much as possible because these do not store static electric charges as much as synthetics 3 Keep plastic vinyl and Styrofoam materials such as plastic or Styrofoam cups cup holders cigarette packages cellophane wrappers vinyl books or folders plastic bottles and plastic ash trays away from the control the modules and the work area as much as possible 4 Do not remove the printed circuit board PCB from the control cabinet unless absolutely necessary If you must remove the PCB from the control cabinet follow these precaution
63. sion is to serve the users of Woodward controls as described here A Full Service Distributor has the primary responsibility for sales service system integration solutions technical desk support and aftermarket marketing of standard Woodward products within a specific geographic area and market segment An Authorized Independent Service Facility AISF provides authorized service that includes repairs repair parts and warranty service on Woodward s behalf Service not new unit sales is an AISF s primary mission A Recognized Engine Retrofitter RER is an independent company that does retrofits and upgrades on reciprocating gas engines and dual fuel conversions and can provide the full line of Woodward systems and components for the retrofits and overhauls emission compliance upgrades long term service contracts emergency repairs etc A Recognized Turbine Retrofitter RTR is an independent company that does both steam and gas turbine control retrofits and upgrades globally and can provide the full line of Woodward systems and components for the retrofits and overhauls long term service contracts emergency repairs etc A current list of Woodward Business Partners is available at www woodward com support Woodward 40 Manual 36526F DPG 21XX 00X Digital Controllers Woodward Factory Servicing Options The following factory options for servicing Woodward products are available through your local Full Service Distributo
64. st apply power to the controller but do NOT start the engine b Second measure the duty cycle across the ACT terminals No 3 and No 4 The reading should be 5 for 5 If the reading is 95 then reverse the leads Use a PC running the Universal PST application and read the value of the PWM command in the View Status panel when the engine is cranking Note from the Universal PST startup screen press the View Status button then press the Start Monitoring button to begin reading values Woodward 17 Manual 36526F DPG 21XX 00X Digital Controllers Chapter 4 Universal PST Ry Introduction The Universal Parameter Setup Tool Universal PST is a Microsoft Windows application available from Woodward that enables you to adjust controller parameter settings and monitor controller operation Universal PST also includes a graphical chart recorder that displays engine speed in real time This provides a visual representation of how the engine speed changes in response to changes in load which can be very helpful when tuning the controller This chapter provides the information needed to use a computer with your controller Here you will find instructions for acquiring installing and running the Universal PST on your PC Also described is information for obtaining or constructing the communications cable needed to connect the controllers COMM port to your computer s serial port Features Universal PST features include e Aut
65. startup sequence the controller increases the engine speed from the engine s crank speed to the active target speed at the STARTUP RATE specified If the IDLE HOLD TIME is nonzero the initial target speed will be the IDLE SPEED After the IDLE HOLD TIME expires the controller then uses the ACCEL RATE to ramp the engine to the selected set soeed REMOTE SPEED POT or SET SPEED A The startup sequence is complete once the engine speed reaches the selected set speed 3 14 Accel Rate optional This rate specifies how fast the controller should increase the engine s speed when a new higher target speed is made active The parameter value is specified in Hertz 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 at 3960 Hertz The controller 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 Speed 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 3 15 Decel Rate optional The Decel Rate specifies how fast the controller should decrease the eng
66. t Woodward P N 8447 1003 contains the latest version of Universal PST on CD ROM a DB 9 Modular Adapter and modular cable Contact the Woodward sales department to request a DPG Software Calibration Kit for a nominal charge Telephone 847 967 7730 Downloading Universal PST The Universal PST application is also available to download from the Woodward Software Products page at www woodward com IC Software Use the Select a Product drop down menu in the center of the web page to select DPG 2xxx digital governors then press the Go button Download Software Products Select a product specifications or do Select a Product D ap AtlasPC 3 06 1 Field Upgrade 4 AtlasPC Control Service Packs Coder 2 08 autH Coder 2 09 DeviceNet Electronic Data Sheets EDS de oad the latest se 2xxx digital governors A EGCP 2 Tools fed software EM LQ Driver Interface Program GAP Editor Monitor sitem CAP Programmer 3 03 SES GAP Programmer 3 04 EI This will automatically redirect you to the Universal PST download page where you can click on the word Download to begin the download process Once you are logged into the Woodward download site you are presented with the File Download dialog box shown below or one similar Click the Save button and choose a folder to save the download to File Download S xi C Some files can harm your computer If the file information below E
67. the control s power input is not designed to withstand a charging system load dump heavy inductive kickbacks or heavy surge type pulses If the control is installed outside its intended usage as described in this manual centralized voltage pulse suppression should be implemented to help protect the control and other components on the bus See Chapter 6 Installation Instructions COMM Port The COMM port is intended to be a service port with only temporary connection during service or initial configuration The COMM port is susceptible to some EMC phenomena and possible unintentional battery return currents 1 Battery return B is also the communication signal common typically PCs connect the communication signal s common to protective earth The PC grounding can provide an unintended return path for B currents If B and the PC are grounded to protective earth a communication isolator should be used between the PC and the control Damage to the PC or control and or unintended operation may result from a broken battery return wire or the parallel path 2 The pins inside the COMM port plug are susceptible to damage by ESD discharges static electricity arcs Care should be taken not to touch them with tools or put fingers into the port Always touch your hand or tool to a grounded piece of metal discharge ESD prior to coming in contact with the communication port 3 The input is susceptible to RF noise such as switching tran
68. the controller s target speed The default value for SET SPEED B is 1000 MPU Hertz 25 Hertz ignition The SET SPEED B parameter s adjustable range extends from SET SPEED B MIN to SET SPEED B MAX See the Installation Instructions chapter for details about using the speed select feature 3 4 Idle Speed optional DPG 2101 00X and DPG 2146 00X Models The IDLE SPEED is the controller s target speed for the IDLE HOLD TIME when the engine is started When the idle hold timer reaches zero the target speed will become SET SPEED A DPG 2145 00X and DPG 2155 00X Models The IDLE SPEED is the controller s target speed for the IDLE HOLD TIME when the engine is started When the idle hold timer reaches zero the target speed will be 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 20 Hertz ignition The IDLE SPEED parameter s adjustable range extends from IDLE SPEED MIN to IDLE SPEED MAX Woodward 9 Manual 36526F DPG 21XX 00X Digital Controllers 3 5 Proportional required The proportional term is one of the interrelated PID terms SES Proportional value that determine how well a Se H Increases output response to a step DPG controller governs the AAN change in error 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 size of the c
69. these oscillations will have lower amplitude With more cylinders there is less time for the 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 filtering is needed The less rotational mass the more filtering is needed For installations using a magnetic pickup to sense engine speed 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 Woodward 11 Manual 36526F DPG 21XX 00X Digital Controllers 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 No _of_flywheel_teeth No _of_engine_cylinders 0 75 speed_filter_value For installations using ignition pulses to sense engine speed It is recommended that the Speed Filter be at least equal to the number of ignition pulses per one revolution of the engine A good starting point would be 2 times the number of ignition pulses per one revolution of the engine pulses_per_rev 2 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 one tenth of a second During the
70. up when the idle hold timer is running This overall gain term is adjustable from 01 to 99 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 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 controller 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 controller s response to speed changes e Too little filtering can make the controller 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
71. urrent Value and the parameter s Default Minimum and Maximum values To modify a parameter s current value it must first be selected Do this by double clicking the left mouse button on a cell in the table that is at the intersection of the parameter s row and the Value column The selected cell will be highlighted and the value can now be modified When done modifying the value press the computer keyboard s lt Enter gt key to transmit the new value to the controller In the figure shown below the Set Speed A value has been selected for editing DPG 2201 Parameter Setup Name Value _ Default Minimum Maximum 0 0 0 0 1 Number of Teeth 2 Set Speed A 3736 1000 10 11000 3 Set Speed B 1000 1000 10 11000 4 Idle Speed 477 500 10 11000 5 Proportional 40 25 1 99 6 Integral 50 50 0 99 7 Derivative 25 25 0 99 Woodward 23 Manual 36526F DPG 21XX 00X Digital Controllers Parameter Help To get help on a particular parameter single click the left mouse button on a parameter s Value then press lt Ctrl gt lt F1 gt on the computer s keyboard lt Ctrl gt lt F1 gt means press and hold the lt Ctrl gt key while the lt F1 gt key is pressed and released This opens the DPG online help file and automatically jumps to the selected parameter s help page NOTE Complete online help for each DPG controller is also accessible by selecting either Governor Help Contents or Parameter Definitions from t
72. when any of the following are present 1 The battery can be disconnected and an unsupressed high current battery charging system is in use 2 Unsuppressed switched inductive loads are in parallel or series with the control power 3 The input power is derived from a distribution system or it is more than 32 8 10m from the control to the main power source Woodward 36 Manual 36526F DPG 21XX 00X Digital Controllers Make Brake contact may DPG Control cause e ane o doa Bus Large amp Short Length e P Optional K Switched source D Joyenjoy a peo anonpu AAeey 19410 10 10 eNn oY D Local Bus Large amp Short Length Application Poor Practice ED D Long Cable Unintended Application Poor Practice 24V buss may use two WGC p n 1682 1059 12V buss may use two 15KP13CA parts WGC p n 1682 1061 AgIue passaiddns seng jl papseu q jou Aeyy _ 15KP17CA parts b ce ae A Discrete parts are available from V47ZA7 MOV to Woodward as chassis at the control 12V 8923 1271 KIT 24V amp 12V system 24V 8923 1272 KIT WGC p n 1688 411 LTT o D E o ZE O O a 5 2 O 2 Z E SE 5 2 B KS oO O o 2 Wi D D ss 2 fa 2 w Cc E E st HL N Figure 5 Centralized Suppression Implemented at the System Level FIGURE 5 NOTES L

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