DPG-210X Digital Controllers
Contents
1. MPU signal in Hertz Engine rom x of Flywheel Teeth 60 sec A magnetic pickup or MPU provides the engine speed signal to the controller in Hertz The controller compares this signal to the user s programmed set speed also in Hertz to determine whether fuel to the engine needs to increase or decrease in order for the engine speed to equal the target speed The fuel flow is controlled with an actuator The actuator may be part of a throttle body or connected to a separate throttle body with mechanical linkage The controller provides a drive signal to the actuator to cause more or less fuel to flow through the throttle body thus affecting the engine s speed Features include e Isochronous speed control e User friendly operator adjustable e Precision frequency control 0 25 e Superior temperature stability e Reverse battery protection e Input voltage range 9 30 Vdc Actuator Compatibility DYNA 2000 DYNA 70000 DYNA 8000 APECS 0150 EPG 512 DYNA 2500 DYNA 70025 DYNA 8200 APECS 0250 EPG 1724 DYNA 10141 DYNA 8400 APECS 0300 Part Numbers Available DPG 2102 DPG 2104 DPG 2107 DPG 2103 DPG 2105 Please see Chapter 3 for user adjustable factory settings Woodward 1 DPG 210X Digital Controllers Manual 36543B Chapter 2 Controller Specifications The controller s main electrical and mechanical specifications are listed here along with several performance characteristics Electrical 7 A Maximum conti2. 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 11 DPG 210X Digital Controllers Manual 36543B Chapter 5 Diagnostics amp Troubleshooting Troubleshooting Chart PROBLEM DETECTION CORRECTIVE ACTION Check battery voltage at controller If no voltage check System appears dead with power switch turned ON connections to battery No LED fails to move Measure DC battery voltage Correct wiring Check polarity of the Bat and Bat Check linkage Manually operate Free linkage linkage to see that it is not sticking or binding No signal or weak signal from Check for damage to or magnetic pickup Measure AC improper adjustment of LED blinking slow and engine being cranked voltage between terminals MPU magnetic pickup Replace or and MPU on the controller while readjust cranking engine Voltage should be 2 5 volts RMS or greater AC input impedance of meter must be 5000 ohms Check actuator output with power Replace controller if 95 of ON to controller Measure the battery voltage is not present following terminals on the controller box with respect to Bat All points should read Battery 95 A 1 Act to Bat Battery voltage 2 Act to Bat Battery LED blinking fast voltag
3. 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 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
4. down device is required to prevent loss of engine control which may cause personal injury and or equipment damage Please read this entire procedure first before making any adjustments 1 With no power to the governor verify that gain is set to 20 or factory default 2 Start the engine and adjust the speed by pressing increase decrease speed buttons until targeted speed is achieved or engine begins to hunt Use a customer supplied tachometer or frequency meter to verify speed 3 Ifthe engine begins to hunt adjust the gain to remove the hunt The isochronous governor holds a fixed speed If the engine varies speed slowly oscillation rate lt 1Hz then increase the gain in small increments until oscillation disappears For a fast hunt which is defined as a 1Hz or greater oscillation decrease the gain in small increments This adjustment may need to be made as engine speed is adjusted to the target speed Woodward 5 DPG 210X Digital Controllers Manual 36543B 4 Once the engine is set to the target speed it will be necessary to upset the engine governor to verifv the performance of the svstem This can be done by a very fast interruption too long may cause shutdown of the MPU signal from the terminal or by bumping the linkage if available 5 If after the engine governor has been upset the engine begins to hunt adjust the gain For a slow hunt increase the gain if the hunt is fast decrease the gain If the engine
5. response is slow slowly increase the gain at 1 2 division increments If the engine droops at full load decrease the gain until the frequency is at target When gain adjustments are made it will be necessary to recheck the performance of the engine by repeating Step 4 This will help set the governor response to fuel burn rate of the engine Integral Limit Setting The INTEGRAL LIMIT is another adjustment that is available The integral limit setting should only be adjusted when the engine is not running The factory setting for the integral limit initially NO TIC E equals 75 DPG 2102 DPG 2103 DPG 2104 76 DPG 2105 or 50 DPG 2107 The integral limit can be set anywhere between 20 and 100 The integral limit feature may be useful in minimizing engine speed overshoot related to integral windup When the engine is unable to carry a load the integral term of the PID equation will continue to grow which can cause a delay in reducing fuel to the engine when the load is removed or reduced The INTEGRAL LIMIT setting is used to stop integration whenever the actuator drive signal is above a specific percentage of the maximum signal possible In the INTEGRAL LIMIT ADJUST MODE the potentiometer is used to set the actuator drive signal percentage above which integration is stopped INTEGRAL LIMIT ADJUST MODE is active when the LED is not blinking and on See the following procedure for instructions describing how to adjust the integ
6. F b Remove actuator leads from controller c Connect actuator leads to Bat and Bat direct to battery 2 Actuator should go to full fuel 3 Internal style actuator should give a Click noise when actuator hits the stops 4 External style actuator should be visibly in the fuel position 5 The actuator should go to full fuel and the DC voltage must be greater than 80 of supply 24 Vdc 80 19 2 Vdc 12 Vdc 80 9 6 Vdc NOTE With the power switch in the OFF position remove actuator leads from battery and reconnect actuator leads to controller when testing is completed If actuator doesn t make full fuel then check actuator leads If voltage is less than specified check for loose or poor connections to battery or get larger supply leads or larger power supply Woodward 13 DPG 210X Digital Controllers Manual 36543B Chapter 6 Service Options Product Service Options If you are experiencing problems with the installation or unsatisfactory performance of a Woodward product the following options are available e Consult the troubleshooting guide in the manual e Contact the manufacturer or packager of your system e Contact the Woodward Full Service Distributor serving your area e 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
7. Higher gain settings are more sensitive to changes in engine speed than are lower gain settings Gain settings too high or too low can hinder the controller s ability to maintain a steady engine speed at the set speed As a general rule low set speeds require low gain settings Likewise higher set speeds require higher gain settings For example A set speed of 5040 Hertz will typically require a gain setting between 40 and 60 while a set speed of 3000 Hertz often works best with a gain setting between 20 and 40 GAIN ADJUST MODE is active when the LED is blinking either fast or slow If the controller is powered and the LED is on and not blinking the controller is currently in INTEGRAL LIMIT ADJUST mode To put the controller back in GAIN ADJUST MODE do one of the following e Turn the power to the controller off then back on or e Press and hold for approximately 5 seconds both the INC and DEC buttons until the LED starts blinking then release the buttons Adjusting Engine Set Speed and Gain Setting Together The DPG 210X is a very versatile controller The speed range is 1000 Hz to 11 000 Hz The wide range of speed adjustment also has wide range of gain adjustments The speed adjustment and gain adjustment ranges are in direct relationship with each other Therefore when adjusting the controller speed it will be necessary to adjust gain also N O TI G E Controllers are factory adjusted to 1000 Hz An independent overspeed shut
8. ML WOODWARD Technical Manual 36543 Revision B Original Instructions DPG 210X Digital Controllers Programmable Controllers for Isochronous Generators Installation and Operation Manual IMPORTANT injurv hazards Obev all safetv messages that follow this svmbol to avoid possible injurv or death DANGER Indicates a hazardous situation which if not avoided will result in death or serious injury DEFINITIONS WARNING Indicates a hazardous situation which if not avoided could result in death or serious injury CAUTION Indicates a hazardous situation which if not avoided could result in minor or moderate injury NOTICE Indicates a hazard that could result in property damage only including damage to the control IMPORTANT Designates an operating tip or maintenance suggestion U This is the safetv alert svmbol It is used to alert vou to potential personal The engine turbine or other tvpe of prime mover should be equipped with an overspeed shutdown device to protect against runawav or damage to the prime mover with possible personal injurv loss of life or propertv damage The overspeed shutdown device must be totallv 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 performed before installing operating or servicing this equipment P
9. Woodward systems and components for the retrofits and overhauls emission compliance upgrades long term service contracts emergency repairs etc e 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 directory cfm 14 Woodward Manual 36543B DPG 210X Digital Controllers Woodward Factorv Servicing Options The following factorv options for servicing Woodward products are available through vour local Full Service Distributor or the OEM or Packager of the equipment svstem 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 vou to request and receive a like new replacement unit in minimum time usuallv 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 t
10. 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 10 Woodward Manual 36543B DPG 210X Digital Controllers Make Brake contact mav DPG Control cause Surge Pulses Jojenjov Si peo SAIJONPUI AAB9U 19470 JO JOJENJOV Local Bus Large amp Short Length Switched source aw ch G ae Optional 7 NI Long Cable Unintended Application Poor Practice A o Long Cable Unintended Application Poor Practice jl p p u aq jou Aew uoissaiddns li 12V buss mav use two WGC p n 1682 1061 WGC p n 1682 1059 15KP13CA parts 24V buss may use two 15KP17CA parts A je4ju99 possojddns eeng a Local Bus Large amp Short Length 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 D D L G C O O Q e O L D Cc D O L e L D lt oe N Figure 2 Centralized Suppression Implemented at System Level FIGURE 2 NOTES 1 Power and return cables t
11. 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 transients 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 lii DPG 210X Digital Controllers Manual 36543B Electrostatic Discharge Awareness All electronic equipment is static sensitive some components more than others To protect these components from static damage vou 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 t
12. e 1 5 Vdc but actuator does not B Following checks are move to open terminals on the actuator and Bat on the controller 1 Low voltage 1 0 2 0 Vdc at either actuator terminal 2 Battery voltage at both Broken actuator lead actuator connectors 3 Battery voltage at one actuator Check actuator lead but not at the other Broken actuator lead Check controller and actuator wiring Correct or replace actuator 1 Turn off power to controller wiring Actuator lever goes to full 2 Remove wiring to actuator Replace controller because it fuel whenever the power terminals on controller and measure Should not cause actuator lever is turned ON and engine resistance between each lead and 10 90 to full fuel with engine not is not running chassis ground 0 0 ohms indicates Unning shorted leads 3 Normal resistance 12 Woodward Manual 36543B DPG 210X Digital Controllers Troubleshooting Chart cont d PROBLEM DETECTION CORRECTIVE ACTION Engine hunts during operation External linkage 1 Linkage or rod end bearing sticking or binding 2 Improper linkage arrangement Stroke too short or improper non linear linkage used 3 Improper governor adjustment Lubricate or replace See installation information Readjust calibration Engine hunts during operation Internal External linkage 1 Inadequate power supply voltage a Turn power switch OF
13. e Rd Fort Collins CO USA 80525 Model Name s Number s DPG 210X 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 21 09 Date 5 09 1183 Rev 15 22 Jan 2009 00327 04 EU 02 06 doc li Woodward Manual 36543B DPG 210X 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
14. he 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 credit 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 opti
15. he terminals are tightened properly to secure wires Woodward 9 DPG 210X Digital Controllers Manual 36543B Centralized Suppression The control meets the regulatorv 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 when any of the following are present 1 The battery can
16. lowing 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 1 The unit is powered 2 The unit is in the GAIN ADJUST MODE the gain setting can be adjusted 3 There is no MPU Magnetic Pick Up signal This means the engine is not running If the engine is running and the LED is blinking slow then refer to the troubleshooting chapter for help in diagnosing why the MPU signal to the controller is missing A fast blinking LED indicates all of the following 1 The unit is powered 2 The unit is in the GAIN ADJUST MODE the gain setting can be adjusted 3 There is an engine speed signal at the controller s MPU terminals When the LED is on and not blinking it indicates the following 1 The unit is powered 2 The unit is in INTEGRAL LIMIT ADJUST MODE The integral limit setting can be adjusted In this operating mode it is not evident from the LED whether the engine is running or not The engine should not be running when adjustments to the integral limit are being made 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 fa
17. nnnanrnnnnnnnn nn na 6 CHAPTER 4 INSTALLATION INSTRUCTIONS snsennnnnnnnnnnnnmnnmnnmnnnnmnnnenmnnnznt 8 Recommended Mounting Le AKAAA EEA EA KANEEEAEEKENEEEEZZEEEENEEZTT 8 Terminal Descriptions E 8 NAV SATA DIa l E 9 Centralized Suppression cccccceccseeeeseeceecceeeseeeeeeeeeeaeeeseeeeeeseessuaeeeeeesessaaaasess 10 CHAPTER 5 DIAGNOSTICS amp TROUBLESHOOTING csccsecceecneeseseneeneeeeseens 12 Troubleshooting Chart 12 CHAPTER 6 SERVICE OPTIONS i e i eege 14 Product Service ee re 14 Woodward Factory Servicing Options ss ss nennnnnnnnnnnnnznnnnnnnnznnnnzznnnznnnnnnnzzznznna 15 Returning Equipment for Repair nn nanna nanna nar nan nn nnnnn nn nn 15 PACKINO T GO de a eaecemaaadancivereanadesmeacsoce ss 16 Replacement Parts dinsinewiancsanvainiadanhetindsanmauhseduosaindnahsaiiseaidusatouniendadcwtatbsstentaueseacduades 16 Erigineerina Le 16 How to Contact WoOdWaId ccccccccecceseseeeeeeeeeaeeseeeeeeeeeesaaeseeeeeeeeesseeeeeeeeeesaaas 17 TECHNICA ASSISTAING S aceitei aan EE AR ERSEN REARS 17 Illustrations EE Figure 1 Wiring Diagram for DPG 210X Controllers ss nnnnnnnzzznnnnnnnnnna 9 Figure 2 Centralized Suppression Implemented at System Level 11 Woodward i DPG 210X Digital Controllers Manual 36543B Regulatorv Compliance Declaration of Conformitv DECLARATION OF CONFORMITY Manufacturer s Name WOODWARD GOVERNOR COMPANY WGC Manufacturer s Address 1000 E Drak
18. nuous 14 A not to exceed ten seconds 0 007 He 150 70 Input Signal Startup 0 1000 Hz Normal Operation 1000 11 0000 Hz Input Signal from Magnetic Pickup 2 5 VAC RMS minimum during cranking nput signa vom moane s 40 V minimum during cranking Ignition System All cabling for these controllers is limited to less than 3m 9 84 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 180 F 40 C to 82 C e Suitable for mounting per SAE J1455 l _ Set speed using increase decrease Controller Adjustment pushbuttons and Gain adjustment 270 Oil water and dust resistant via conformal coating and die cast enclosure Performance _ 25 over ambient operating Steady State Speed Band EE E Temperature Stability 0 007 Hz 158 F 70 C 2 Woodward Manual 36543B DPG 210X Digital Controllers User Interface Operation Kevpad DPG 210X controllers provide two buttons for adjusting the engine set speed e INC increases the Set Speed e DEC decreases the Set Speed Gain Potentiometer The DPG 210X controller provides a potentiometer labeled GAIN for two separate adjustments e Overall gain setting e Integral limit setting LED The LED Light Emitting Diode is used as a status and operating indicator When the LED is off it indicates that one of the fol
19. o telephone for technical assistance you will need to provide the following information Please write it down here before phoning Your Name Site Location Phone Number Fax Number Engine Turbine Model Number Manufacturer Number of Cylinders if applicable Type of Fuel gas gaseous steam Rating Application Control Governor 1 Woodward Part Number amp Rev Control Description or Governor Serial Number Control Governor 2 Woodward Part Number amp Rev Control Description or Governor Serial Number Control Governor 3 Woodward Part Number amp Rev Control Description or Governor 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 17 DPG 210X Digital Controllers Manual 36543B 18 Woodward We appreciate your comments about the content of our publications Send comments to icinfo woodward com Please reference publication 36543 ML WOODWARD 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 location
20. o the control are routed together to minimize 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 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 the majority of the likely pulses
21. on is applicable to mechanical products only 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 authorization 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 Woodward 15 DPG 210X Digital Controllers Manual 36543B Packing a Control Use the following materials when returning a complete control e protective caps on any connectors e antistatic protective bags on all electronic modules e packing materials that will not damage the surface of the unit e atleast 100 mm 4 inches of tightly packed industry approved packing material a packing carton with double walls e a strong tape around the outside of the carton for increased strength To prevent damage to electronic components caused by improper N O Tl CE handling read and observe the precautions in 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 n
22. our products interface For information on these services please contact us via telephone email us or use our website www woodward com support 16 Woodward Manual 36543B DPG 210X Digital Controllers How to Contact Woodward For assistance call one of the following Woodward facilities to obtain the address and phone number of the facilitv nearest vour location where vou will be able to get information and service Electrical Power Svstems PHONE NUMBER 455 19 3708 4800 486 512 6762 6727 FACILITV Germanv Kempen 49 0 21 52 14 51 Stuttgart 49 711 78954 0 91 129 4097100 81 43 213 2191 82 51 636 7080 48 12 295 13 00 1 970 482 5811 Poland United States Engine Systems PHONE NUMBER 55 19 3708 4800 86 512 6762 6727 FACILITY Germany Stuttgart 49 711 78954 0 91 129 4097100 81 43 213 2191 82 51 636 7080 The Netherlands 31 23 5661111 United States 1 970 482 5811 Turbine Systems PHONE NUMBER 55 19 3708 4800 86 512 6762 6727 91 129 4097100 81 43 213 2191 82 51 636 7080 48 12 295 13 00 The Netherlands 31 23 5661111 United States 1 970 482 5811 FACILITY You can also contact the Woodward Customer Service Department or consult our worldwide directory www woodward com support directory cfm for the name of your nearest Woodward distributor or service facility Technical Assistance If you need t
23. ractice 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 svstem that uses an alternator or batterv charging N O TI C E device make sure the charging device is turned off before disconnecting the batterv from the svstem To prevent damage to electronic components caused bv improper handling read N O TI C E and observe the precautions in Woodward manual 82715 Guide for Handling and Protection of Elect
24. ral limit setting Adjusting the Integral Limit The engine should not be running when adjustments to the integral limit are made Follow the steps below to adjust the integral limit Apply power to the governor 2 Record the current GAIN potentiometer setting 3 Press both the DEC and INC buttons simultaneously for at least 5 seconds and the LED will stop flashing and remain turned ON 4 The system is now in the INTEGRAL LIMIT adjust mode and the buttons can be released 5 Turn the potentiometer to the desired position for example to set the INTEGRAL LIMIT to 50 adjust the GAIN potentiometer to 50 6 Woodward Manual 36543B DPG 210X Digital Controllers 6 Press both the DEC and INC buttons simultaneously for at least 5 seconds and the LED will start flashing again 7 The system has now been returned to the GAIN adjust mode and the buttons can be released 8 Return the GAIN potentiometer to the setting recorded in Step 3 INTEGRAL LIMIT adjustment is complete Woodward DPG 210X Digital Controllers Manual 36543B Chapter 4 installation Instructions KEN Recommended Mounting The DPG 210X controller is designed to be panel mounted and its chassis electricallv 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
25. rays 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 precautions e Do not touch any part of the PCB except the edges 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 antistatic 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 antistatic protective bag To prevent damage to electronic components caused by improper handling read and observe the N O TI CE precautions in Woodward manual 82715 Guide for Handling and Protection of Electronic Controls Printed Circuit Boards and Modules iv Woodward Manual 36543B DPG 210X Digital Controllers Chapter 1 General Information Introduction DPG 210X controllers can be used on both diesel and gas engines Thev can operate over a frequencv range of 1000 to 11 000 Hz and over a nominal voltage range of 9 to 30 Vdc Engine governing is adjustable over a wide range of engine set speeds An engine s set speed also known as its target speed can be anv frequencv from 1 000 Hertz to 11 000 Hertz The following formula shows the relationship between engine rpm and Hertz
26. ronic Controls Printed Circuit Boards and Modules 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 2010 All Rights Reserved Manual 36543B DPG 210X Digital Controllers Contents EE REGULATORY COMPLIANCE 1ccccccccsssssseeeecsenseeeeeeseesseessensoessesesnsensseeeseooes l Declaration of Conformity ccccccccecsecaeeeeeeeeeeeeesaeeeeseceeeeeesaeeeeeeeeeeessaeeaeeeeeeeeesaas i ELECTROSTATIC DISCHARGE AWARENESS srennannannannnnmnnannnnnnnnnnnmnnzanzn tn IV CHAPTER 1 GENERAL INFORMATION kx ENNER ENNEN E NENNEN KKK KKK KEREN KKK KKK 1 PVA ONG Mase e een else aces A RA 1 CHAPTER 2 CONTROLLER SPECIFICATIONS srnnennnnnnnnnznnnnnnznnnnemnnnnnnnznzznn 2 User Interface Operation 3 Keypad EE 3 Gain Potentiometer sieupna EEEE 3 LED EE 3 CHAPTER 3 PARAMETER REFERENCE xx NKRKR KREE ENNEN EK KK EK KEREN KKK KKK 4 Set Speed and Gain Settings L snnnnnnnnnnn nn nnnnnnnn nanna arr nar nnEnn nn nn nnnnnnEnnnntnnn nn 4 Adjusting Engine Set Speed and Gain Setting Together 5 Integral Limit Seting EE 6 Adjusting the Integral Limit sen ennennnennnnnnnnznnnnnnnnnnnnnnn
27. s is available on our website 201 1 2 Skokie
28. ster than the slow blink rate Woodward 3 DPG 210X Digital Controllers Manual 36543B Chapter 3 Parameter Reference KEE ee DPG 210X controllers have three user adjustable parameters Set Speed Gain and Integral Limit The table below shows the factory minimum and maximum settings for these parameters PARAMETER FACTORY MINIMUM MAXIMUM SETTING SETTING SETTING Set Speed 1 000 Hertz 1 000 Hertz 11 000 Hertz DPG 2102 DPG 2103 9 Integral Limit DPG 2104 e 20 100 DPG 2105 6 The table below shows the factory settings for PID PID FACTORY SETTINGS DPG MODEL Kp Ki Kd Proportional Gain Integral Gain Derivative Gain orcas on nm mens on rm IO e l Set Speed and Gain Settings The SET SPEED and GAIN adjustments work together These adjustments are made while the engine is running NOTE The factory setting for the SET SPEED is 1000 Hertz The factory setting for the GAIN potentiometer is 20 The INC and DEC buttons are active whenever the controller is powered The set speed is increased using the INC button A momentary INC button press and release will increase the set speed by 1 Hertz Press and hold the INC button to increase the set speed rapidly The set speed is decreased using the DEC button 4 Woodward Manual 36543B DPG 210X Digital Controllers The gain adjustment is used to modifv how fast the controller responds to engine speed changes due to changing loads on the engine
29. that exceeds the mechanical specifications outlined in Chapter 2 of this manual Terminal Descriptions FUNCTION Battery positive 9 30 Vdc ACT Actuator drive output Magnetic pickup signal input MPU Magnetic pickup ground SHIELD Ground connection for cable shielding KI ACT Actuator drive return 8 Woodward Manual 36543B DPG 210X Digital Controllers Wiring Diagram Cabling for the DPG 210X controller is limited to less IM PO RTA NT than 3m 9 84 Power cabling is limited to less than 10m 32 8 in total length The wiring diagram below shows specific cable tvpes required Dimensions are in inches Dimensions in brackets are millimeters 4 56 MAX 115 8 eolt O15 4 062 015 5 86 0 38 103 1740 38 AX DB 72194 015 5 5640 38 FEIE P 013 5 8640 38 P N DPG 210X sa i O 3 81 MAX 96 8 wW k WOODWARD 3 312 015 84 1240 38 14 AWG TWISTED 22 AWG TWISTED SHIELDED 14 AWG TWISTED Figure 1 Wiring Diagram for DPG 210X Controllers AN 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 CE e Do not tin the leads before placing them into the terminals e Ensure t
30. umber s XXXX XXXX that is on the enclosure nameplate e the unit serial number which is also on the nameplate 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 assistance 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
31. 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 mission is to serve the users of Woodward controls as described here e 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 e 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 e 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
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