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DPG-2201-00X Digital Controllers

1. MANUFACTURER Signature Ge i K if ppa A PYS PF d e dba ram Douglas W Salter Full Name Engineering Manager Position WGC Fort Collins CO USA Flace Date 5 09 1183 Rev 10 15 Jul 05 Woodward 0032 T 04 EU 02 05 dac DPG 2201 00X Controllers Manual 36523G 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 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 im
2. When the value being displayed by the two 7 segment LEDs is blinking PARAMETER SELECT MODE is active When the value displayed is not blinking the selected parameter s value is being displayed and the user interface is in PARAMETER EDIT MODE The decimal points further indicate which half of a 4 digit value is being displayed and whether editing is allowed The right digit s decimal point is used to indicate that the lower 2 digits of a value the tens and the ones digits are being displayed When the right decimal point is blinking it means that the value can be modified using the INC key or the DEC key No blinking means that editing is not allowed or is password protected The left dote decimal point is used to indicate that the upper 2 digits of a value the thousands and the hundreds digits are being displayed The upper 2 digits are always view only so the right decimal point does not blink Changes to the upper digits occur when a parameter s lower digits overflow or underflow during editing An overflow occurs when the value 99 is displayed and the INC key is pressed assuming this is not the parameter s maximum value This will cause the displayed value to become 00 while the non displayed value in the parameter s upper 2 digits will be increased by one You can verify this by pressing both INC and DEC at the same time to view the new value in the upper digits For example If the full 4 digit value of the parameter you are
3. Manufacturer s Name Manulaclurer s Address Model Name s Number s Conformance ta Directive s Applicable Standards WOODWARD GOVERNOR COMPANY WGC Industrial Controls Group 1000 E Drake Rd Fort Collins CO USA 80525 DPG 2201 002 DIG 2201 001 DPG 2302 002 DPG 3302 001 DPG 2345 001 DPG 2345 002 89 336JEEC COUNCIL DIRECTIVE of 03 May 1989 on the approximation of the laws of the Member States relating to electromagnetic compatibility and all applicable amendments EN 61000 6 4 2001 EMC Part 6 4 Generic Standards Emissions for Industrial Envirotunents EN 61000 6 2 2001 EMC Part 6 2 Generic Standards Immunity tor Industrial Environments EN ISO 14982 1998 Agricultural and forestry machinery Electromagnetic compatibility Test methods and acceptance criteria Deviations Used ISO 10605 2001 E ISO 11452 2 2004 ISO 11452 4 2005 and ISO 7637 2 7004 Pulse 1 passed at EN 14982 levels Pulse Sa 5b omitted handled at the system level EN 13309 2000 Construction Machinery Electromagnetic compatibility of machines with internal electric power supply Dewiations Used ISO 10605 2001 L ISO 11452 2 2004 ISO 11452 4 2005 and ISO 7637 2 2004 Pulse 1 passed at EN 14982 levels Pulse 5a 3b omitted handled at the system level Deviations are addressed in the installation instructions We the undersigned hereby declare that the equipment specified above conforms to the above Directive s
4. Engine Instability With Load Fuel is restricted Check actuator linkage Battery voltage is too low PID values may be too high causing the controller to overreact and make large rapid changes in PWM duty cycle output to the actuator Engine Unable to Carry Rated Load Improve PID tuning Torque limit is set too low Increase the torque limit Fuel is restricted Check actuator linkage Measure the ILS input signal to see if the measurement is between Load Sharing Does Not Work 2 375 VDC and 2 625 VDC Use shielded wiring The No Load and Full Load values are not calibrated Perform the Droop Calibration Procedure Difference between No Load and Full Load calibration values is too small Should be 5 100 for best performance Droop Does Not Work l l l Modify or adjust actuator linkage to increase range of actuator loading If finer droop control is required then use a DPG 2223 00X controller Woodward 43 DPG 2201 00X Controllers Manual 36523G Chapter 8 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 chapt
5. and the lower 2 digits will display 00 3 4 Idle Speed optional 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 either SET SPEED A or SET SPEED B depending on the state of the SPEED SEL input terminal The default value for IDLE SPEED is 500 MPU Hertz The IDLE SPEED parameters adjustable range extends from IDLE SPEED MIN to IDLE SPEED MAX When IDLE SPEED values greater than 9999 are displayed the left most digit uses the capital letter A to represent 10000 and the lower case letter b to represent 11000 For example If IDLE SPEED is set to 11000 then the upper 2 digits will be displayed by the controller as b 0 and the lower 2 digits will display 00 Woodward 11 DPG 2201 00X Controllers Manual 36523G When the No of Flywheel Teeth parameter is used the SET SPEED A SET SPEED B IDLE SPEED OVER SPEED LIMIT SET SPEED A MIN NOTICE SET SPEED A MAX SET SPEED B MIN SET SPEED B MAX IDLE SPEED MIN IDLE SPEED MAX and STARTUP SPEED parameters are displayed as RPM values instead of Hertz values 3 5 Proportional required The proportional term is one of the interrelated PID terms that determine how well a DPG 2201 00X controller governs the engine s speed A speed change creates a speed error the difference between the target speed and the actual speed The proportional gain controls the s
6. 00X PARAMETER NAME DEFAULT MINIMUM MAXIMUM on o o0 0 1 No Of Flywheel Teeth Kana w o o z Set Speed A Set Speed A Set Speed B Set Speed B 5 Proportional sn o emoa ae o Towai 25 o o BOVE SetSpeedA 2 r o e ovc setspeeas an a 100V ide Speed 2 mm mantar o o o owens o o eneen mn mm CO mo me 23 Full Load Cal 1000 o 1000 24 Password 0 Lg Is mi 1 001 100 oO 100 25 Over Speed Limit 15000 0 15000 95 95 32 Duty Cycle Limit 33 Startup Speed 34 Startup Duty Cycle 30 95 Parameters 2 5 6 7 8 11 12 and 33 require adjustment while adjustments to the other parameters are optional 4 See Important Note on previous page Woodward 9 DPG 2201 00X Controllers Manual 36523G 3 1 No of Flywheel Teeth optional This parameter provides the conversion factor needed by the controller to display speeds as RPM values instead of Hertz values Adjusting this parameter is optional To use this parameter correctly you must know the exact number of flywheel teeth that pass by the magnetic pickup in one revolution of the engine Adjusting the No of Flywheel Teeth ter i M P OR TAN T prohibited while the Engine is anang ge The default value of 0 disables Hz to RPM conversions so all set speeds are displayed in MPU magnetic pick up Hertz Setting this parameter to a value other than zero enables Hz to RPM conversion Adjust this paramet
7. ACCEL RATE 500 Hz sec Speed in Hertz STARTUP RATE 250 Hz sec l IDLE SPEE 1500 Hz STARTUP SPEED 500 15 20 25 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 equal 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 s
8. Controllers Manual 36523G the value will automatically continue to be decreased at gradually faster and faster rates until the DEC key is released or the parameter s minimum allowed value is reached When the lower two digits display a 00 pressing the DEC decrease key will cause the lower two digits to display a 99 and the hundreds digit will have been decreased by 1 INC and DEC Keys Together In PARAMETER EDIT MODE the INC and DEC keys are used together to view the value of the upper two digits of a 4 digit number Press and hold both INC and DEC simultaneously to view the value of a 4 digit number s upper two digits Note that the left digit s decimal point is turned on to indicate that the thousands and the hundreds digits are being displayed Release INC and DEC and now the tens and the ones digits are again being displayed Note that the right digit s decimal point is blinking if editing is allowed or just ON if editing is not allowed Note Not all parameters are 4 digit numbers in which case the upper digits will always display 0 0 zero dot zero In PARAMETER SELECT MODE pressing both the INC and DEC keys at the same time will cause all LED segments to be turned on This serves as an LED test Release the keys to resume displaying the parameter ID number LED Display The two 7 segment LED s along with each digit s corresponding decimal point are used to display values and indicate the operating mode of the user interface
9. Droop Calibration Procedure the full load calibration value is less than the no load calibration value then the droop function cannot be used Some actuators may have a current versus position curve that is incompatible with this controller s method of determining actuator position NOTE This parameter is only modified during the Droop Calibration Procedure See the Calibration Instructions chapter for more information 3 24 Password optional The password parameter is used for the following functionalities e controlling password protection e entering calibration modes see Calibration Instructions Password protection is provided to guard against inadvertent parameter changes that may occur whenever the keys are pressed and a parameter modification is not intended The password protection has three possible settings DISABLED LOCKED and UNLOCKED These settings can be modified with built in user interface only not Universal PST DISABLED This setting turns off any password protection Use this setting if password protection is not desired This is the default setting as shipped from the factory Entering a value of 99 sets the password protect parameter to the disabled mode If not already in the UNLOCKED mode the user must get into the UNLOCKED mode in order to enter a 99 to disable password protection When the password protect parameter is selected the LED display will show Pd for 2 seconds indicating the password disabled mo
10. Temperature 40 F to 185 F 40 C to 85 C Oil water and dust resistant via conformal coating and die cast enclosure Weight 12 oz 341 9 e Suitable for mounting per SAE Mechanical Vibration 1455 1 to 500 Hz 5G amplitude Performance Temperature Stability 0 007 Hz 158 F 70 C _ 0 25 over ambient operating Steady State Speed Band temperature range Engine Speed Measurement Range Boch PERSCH Governing Speed Range AN Hertz to 11 000 MPU 3 around the set speed 2 Woodward Manual 36523G DPG 2201 00X Controllers User Interface Operation The user interface has two distinct behaviors that you should familiarize yourself with in order to select parameters and adjust them These behaviors are described in the Operating Modes section below A 4 pushbutton keypad and a 2 digit LED display make up the built in user interface The pushbuttons also called keys are described in the section named Keypad The LED display is described in the section named LED Display Remote access to the controller s parameter settings is available when the controller s COMM port is connected to a computer running our Universal PST application The COMM port provides access to controller settings allowing adaptation to each application during service and initial configuration Operating Modes The user interface operates in two modes PARAMETER SELECT MODE and PARAMETER EDIT MODE For each of these modes
11. 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 C Program Files oodward Universal PS TAPE 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 Reset 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 fi
12. during normal operation NOTE If the value is set too low the engine will not be able to carry its rated load 16 Woodward Manual 36523G DPG 2201 00X Controllers 3 19 Integral Low Limit optional The integral low limit prevents integral windup in the negative direction In other words the integral low limit parameter is used to reduce under speed duration after a long or sustained over speed condition was present The low limit helps reduce the duration and amount of engine under speed by maintaining a minimum actuator position When smaller PWM duty cycle values do not reduce the engine speed any further but an off soeed 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 Use carefully as improper use can prevent the controller from ever reaching the target speed The first line of defense in reducing overspeed or under speed errors is a well tuned controller via the PID terms 3 20 Integral High Limit optional The integral high limit prevents integral windup in the positive direction In other words the integral high limit parameter is used to reduce over sp
13. ends when the Idle Speed is reached Then the Decel Rate is used to ramp the engine speed down to the target speed from the Idle Speed The ramp up will pause at the STARTUP SPEED until the controller senses an MPU signal greater than the STARTUP SPEED This prevents the startup ramp Woodward 15 DPG 2201 00X Controllers Manual 36523G 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 2 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 parameters are displayed as a RPM quantity per second instead of HZ sec I M P OR TAN T 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 Startup Limit optional The startup limit parameter is used to limit the fuel supplied to the engine during startup The default value of 1000 allows the actuator drive signal to use 100 0 of available current Decreasing the value limits the available drive signal
14. is at the intersection Proportional 50 of the parameter s row and the Value Integral 20 CO umn Derivative 10 Overall Gain 10 Ki Slow Fast 1 The selected cell will be highlighted and vt Engine 5i 2 the value can now be modified When nn oe tartup Limit 100 done modifying the value press the Torque Limit ann computer keyboard s lt Enter gt key to integral Low 0 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 Ze Dto 12000 Hz T to 6000 Hz ft st 10 of 1000 Hz Hertz Horizontal Scale in seconds U6o 30 071015 Average 0 0 Chart Recorder Signal Filtering Min EC OCOOOC Max The Vertical Scale options provide three different ways 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 The 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
15. 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 O 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 O TI C E and observe the precautions in Woodward manual 82715 Guide for Handli
16. 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 Engine Does Not Reach The Integral Low Limit setting is too high Return the value to the Set Speed cont d default setting of zero The Integral High Limit setting is too low Return the value to the default setting of 99 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 Takes Too Long to Reach the Set Speed 42 Woodward Manual 36523G DPG 2201 00X Controllers Troubleshooting Table cont d SYMPTOM REMEDY Is the LED decimal point blinking If not enter password Is the selected set speed parameter being modified Engine Does Not Track Speed A PID value or an OVG value is too high Setting Changes A PID value is too low or zero Accel Rate is set too low Decel Rate is set too low Improve PID tuning Use a lower Startup Rate setting Use a lower Startup Limit setting Low MPU signal voltage It should read 2 0 VRMS minimum Excessive Smoke at Startup Gain too low Improve PID tuning Speed filter setting is too high Sluggish Response to Load Changes Improve PID tuning Speed filter setting is too low Fuel is restricted Check actuator linkage Battery voltage is too low Engine Instability With No Load Improve PID tuning
17. 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 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 44 Woodward Manual 36523G DPG 2201 00X Controllers Woodward Factory Servicing Options The following factory options for servicing Woodward products are available through your local Full Service Distributor 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 availabl
18. thereby limiting how far open the actuator can go Increasing the value allows the actuator to open further The value assigned to the startup limit parameter is in units of one tenth of a percent of the actuator s maximum current feedback reading The controller measures actuator drive signal feedback and obtains an approximation of the amperes of current flowing through the actuator Fuel limiting is achieved by setting the maximum level of electrical current allowed to flow through the actuator during engine startup This feature is useful in reducing smoke when starting diesel engines NOTE If the value is set too low the engine may not start 3 18 Torque Limit optional The torque limit parameter is used to limit the fuel supplied to the engine during heavy generator loads or generator overloads The default value of 1000 allows the actuator drive signal to use 100 096 of available current Decreasing the value limits the available drive signal thereby limiting how far open the actuator can go Increasing the value allows the actuator to open further The value assigned to the torque limit parameter is in units of one tenth of a percent of the actuator s maximum current feedback reading The controller measures actuator drive signal feedback and obtains an approximation of the amperes of current flowing through the actuator Fuel limiting is achieved by setting the maximum level of electrical current allowed to flow through the actuator
19. 36523G 3 21 Percent Droop optional The percent droop parameter is used to select droop mode operation and specify the percentage of droop required When the percent droop parameter is set to zero the default setting then droop mode is not active Droop mode is active when this parameter is set to any value from 1 to 100 which corresponds to 0 1 to 10 0 droop The following formula determines the no load droop speed selected_set_speed 1000 value_of_ DROOP 1000 no_load_droop speed For example If 5 droop is desired set the percent droop value to 50 Now if the selected set speed is 1800 RPM then the no load droop speed will be 1800 RPM 1000 50 1000 1800 RPM 0 95 1895 RPM NOTE This parameter can only be modified during the Droop Calibration Procedure See the Calibration Instructions chapter for more information Droop mode relies on knowing the actuator position The actuator s position corresponds to the amount of fuel being delivered to the engine The DPG 2201 00X controller senses electrical current flow through the actuator to determine its position This method of position sensing does not work with all actuators 3 22 No Load Calibration optional The No Load Calibration value is learned during the Droop Calibration Procedure and should not be set manually Once calibrated the no load calibration value indicates the percentage of electrical current relative to the measurable m
20. EL and 5 Vdc 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 pm Parameter Name Default Value 2 sersrecpa mm s PROPORTIONAL e e mesan v e ovc sersreeva a 12 SPEED FILTER note 2 33 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 of 16 is recommended for 6 or 8 cvlinder enaines 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 O 2 Set the overall gain low lt 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 32 Woodward Manu
21. GC p n 1682 1059 5KP13CA parts T WGC p n 1682 1061 papaau aq jou Aey uoissaiddns p Ajjeusa passaiddns ssnq K CC Discrete parts are available 177 from Woodward as V47ZA7 MOV to 12V 8923 1271 KIT chassis at the control 24V8 12V system 24V 8923 1272 KIT WGC pin 1688 411 Be D Be O ce O o Ep Be o _ z a 3 x c1 O Dt w Sa O c o 2 Oo o E a nO ON SD st O xt LO c E st Figure 2 Centralized Suppression Implemented at the System Level FIGURE 2 NOTES 1 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 are dependant 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 pulse
22. I 23 Acquiring Universal EN EE 24 Ice W ut 25 Woodward DPG 2201 00X Controllers Manual 36523G Contents cont d CHAPTER 5 CALIBRATION INSTRUCTIONS 0 ccsscsscneessseneeessenseneesnseneeeeeenes 32 Basic Acdhustmente seercisisiicericraienii en ennienni aria e NAR EEE REEE 32 Tuning Methodologie 32 SAUD SEQUENCE iiA 34 Droop Calibration PDrocecdure a 35 CHAPTER 6 INSTALLATION INSTRUCTIONS cesccscceeesuscnecceseuseneseueeneeeesenes 37 Terminal Descriptions 37 RECOMMENDED MOUNTING 22002302002a nauna ana a KENNEN nauna anna NAAN KAN KK KEREN KK KEREN KENNEN 37 Nian DIO E 38 Geniralized SUDDIESSION EE 39 Display COQE AA AA 41 Troubleshooting RR El EE 42 CHAPTER 8 SERVICE OPTIONS 2270002000200 00008 n4 EE NNN KNEE NNN NAAN ANN NAK AANN NN AAO 44 Product Service OptiOnS aa 44 Woodward Factory Servicing Options a 45 Returning Equipment for Repair cccccsssccccssseeeeneeeeceseeeseaeeeseseseeesseseeesnaneess 45 PCI MAG CON Ola AA AA eens teeta 46 Replacement Parts AE 46 Engineering Gervices a 46 How to Contact VWoocdhward 1a 47 FECANICAL ASSISTANCE E 47 Illustrations D YY Figure 1 Wiring Diagram for DPG 2201 001 and DPG 2201 002 8 38 Figure 2 Centralized Suppression Implemented at the System Level 40 li Woodward Manual 36523G DPG 2201 00X Controllers Regulatory Compliance Declaration of Conformity DECLARATION OF CONFORMITY
23. If the controller s label lists 34 parameters then pressing the INC key when the display is blinking the value 36 will cause the display to wrap around to the first parameter listed and begin blinking the value 01 In PARAMETER EDIT MODE each INC key press will increase a parameter s current value If the INC key is held down while in PARAMETER EDIT MODE the value will automatically continue to be increased at gradually faster and faster rates until the INC key is released or the parameter s maximum allowed value is reached When the lower two digits display a 99 pressing the INC increase key will cause the lower two digits to display a 00 and the hundreds digit will have been increased by 1 DEC decrease Key The DEC decrease key is used to decrease the displayed value In PARAMETER SELECT MODE each press of the DEC key will cause the next lower parameter number to be displayed When the first parameter identification number is reached the next DEC key press will cause the last parameter ID number to be displayed For example If the controllers label lists 34 parameters then pressing the DEC key when the display is blinking the value 01 will cause the display to wrap around to the last parameter listed which in this case is 34 and blink this new value In PARAMETER EDIT MODE each DEC key press will decrease a parameter s current value If the DEC key is held down while in PARAMETER EDIT MODE Woodward 5 DPG 2201 00X
24. W wooDWARD Technical Manual 36523 Revision G Original Instructions DPG 2201 00X Digital Controllers Programmable Controllers for Isochronous Generators with Load Sharing Capability Installation and Operation Manual injury hazards Obey all safety messages that follow this symbol to avoid possible injury 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 f This is the safety alert symbol It is used to alert you to potential personal IMPORTANT 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 performed before installing operating
25. actuator may be required or a different system solution altogether may be needed by your application such as an actuator with a position feedback potentiometer and a supporting controller 36 Woodward Manual 36523G DPG 2201 00X Controllers Chapter 6 Installation Instructions Terminal Descriptions FUNCTION Battery positive 9 30 Vdc Battery negative Actuator drive output Actuator drive return Magnetic pickup signal input Magnetic pickup ground Digital input used to select the target set speed ILS SIGNAL ILS input used to adjust speed 3 SPEED SEL lt x ILS REF 2 5 V Supply voltage around which ILS operates Digital input used to decrease the selected DEC SPEED set speed remotely Acts identically as DEC pushbutton in parameter edit mode Digital input used to increase the selected set INC SPEED speed remotely Acts identically as INC pushbutton in parameter edit mode 5 Vdc OUT Supply voltage for the digital inputs DC power bus cable must be less than 10 meters 32 80 feet All other cables must be less than 30 meters 98 43 feet ES SHIELD Ground connection for cable shielding Recommended Mounting The controller is designed to be panel mounted and its chassis electrically bonded to the same protective reference as the engine structure The mounting should protect the controller from exposure to rain weather and direct sunlight The controller should not be mounte
26. al 36523G DPG 2201 00X Controllers 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 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 ee wf Integration works on the sum of the errors accumulated over time Woodward 33 DPG 2201 00X Controllers Manual 36523G Startup Sequence The following example describes the DPG 2201 00X startup sequence Startup Sequence Example Na SET SPEED A 3500 J
27. alue for SET SPEED A is 1000 MPU Hertz The SET SPEED A parameters adjustable range extends from SET SPEED A MIN to SET SPEED A MAX When SET SPEED A values greater than 9999 are displayed the left most digit uses the capital letter A to represent 10000 and the lower case letter b to represent 11000 For example If SET SPEED A is set to 10750 then the upper 2 digits will be displayed by the controller as A 7 and the lower 2 digits will display 50 3 3 Set Speed B optional SET SPEED B becomes the controller s target speed when the SPEED SEL input terminal 8 is at 5 Vdc terminal 13 and the startup sequence is complete The startup sequence is complete when the target speed and the engine speed reach the set speed When a two position switch is connected between SPEED SEL and 5 Vdc then a closed switch selects SET SPEED B as the controller s target speed If the controller s SPEED SEL input is not used then SET SPEED A is automatically the active target speed after the startup Sequence is completed The default value for SET SPEED B is 1000 MPU Hertz The SET SPEED B parameters adjustable range extends from SET SPEED B MIN to SET SPEED B MAX When SET SPEED B values greater than 9999 are displayed the left most digit uses the capital letter A to represent 10000 and the lower case letter b to represent 11000 For example If SET SPEED B is set to 11000 then the upper 2 digits will be displayed by the controller as b 0
28. ardware you may purchase a calibration kit from Woodward Both download and kit request instructions are described below Obtaining the DPG Software Calibration Kit The DPG Software Calibration Kit Woodward P N 8447 1003 contains a DB 9 modular adapter and modular cable as well as the web address from which the latest version of Universal PST software may be downloaded Contact the Woodward sales department to request a DPG Software Calibration Kit for a nominal charge Downloading Universal PST The Universal PST application can be downloaded 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 controllers then press the Go button Download Software Products Select 4 product below to download trial versions view software product specifications or download the latest service packs for your system Select a Product AtlasPC 306 1 Field Upgrade a AtlasPC Control Service Packs DeviceNet Electronic Data Sheets EDS bed software EM OC Driver Interface Program GAP Editordonitor GAP Programmer 3 03 GAP Programmer 3 04 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
29. aximum that must flow through the actuator to run the engine at the no load droop speed The factory default value is zero so if droop mode is to be used this parameter must be calibrated The no load calibration value must be less than the full load calibration value for proper droop operation If after performing the Droop Calibration Procedure the no load calibration value is greater than the full load calibration then the droop function cannot be used Some actuators may have a current versus position curve that is incompatible with this controller s method of determining actuator position This parameter is only modified during the N O TIC F Droop Calibration Procedure See the Calibration Instructions chapter for more information 3 23 Full Load Calibration optional The Full Load Calibration value is learned during the droop calibration procedure and should not be set manually Once calibrated the full load calibration value indicates the percentage of electrical current relative to the measurable maximum that must flow through the actuator to run the engine at the selected set speed when a full load is being applied to the generator The factory default value is 1000 so if droop mode is to be used this parameter must be calibrated The full load calibration value must be greater than the no 18 Woodward Manual 36523G DPG 2201 00X Controllers load calibration value for proper droop operation If after performing the
30. d When done modifying the value press the computer keyboard s lt Enter gt key to transmit the new value to the controller 28 Woodward Manual 36523G DPG 2201 00X Controllers In the figure shown below the Set Speed A value has been selected for editing DPG 2201 Parameter Setup Hame Value Default Minimum Maximum U D g 0 1 Number of Teeth 2 Set Speed A 3736 1000 10 11000 3 Set Speed B 1000 1000 10 11000 4 Idle Speed A77 500 10 11000 D Proportional 40 265 1 99 6 Integral 50 50 0 99 T Derivative 25 25 0 99 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 Cirl 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 the 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 Alls 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 applicati
31. d on the engine or in an environment that exceeds the mechanical specifications outlined in Chapter 1 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 Woodward 37 DPG 2201 00X Controllers Manual 36523G Wiring Diagram Cabling for DPG 2201 00X controllers is limited to less IMPORTANT than 30m 98 4 Power cabling is limited to less than 10m 32 87 in total length The wiring diagram below shows specific cable types required Dimensions are in inches Dimensions in brackets are millimeters PDDODDDOHDDD sti HT Figure 1 Wiring Diagram for DPG 2201 001 and DPG 2201 002 To prevent damage to the controller make sure that it is wired in accordance with the wiring instructions NO TICE and diagrams in this manual e Do not tin the leads before placing them into the terminals Ensure the terminals are tightened properly to secure wires 38 Woodward Manual 36523G DPG 2201 00X Controllers Centralized Suppression The control meets the regulatory requirements for its intended installations and when installed correctly 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 sy
32. de then the value 00 is displayed The user can then edit the value LOCKED This setting means that password protection is active and only parameter viewing is allowed parameter editing is disabled Enter a value of 22 to set password protect to locked mode For 2 seconds after selection of the password protect parameter the LED display will show PE for this mode and the rightmost decimal point will be ON not blinking then the value 00 is displayed The user can then edit the value UNLOCKED This setting means that password protection is active but parameter editing is allowed Entering a value of 30 while in LOCKED mode will UNLOCK parameter editing The user is free to edit parameters If there is no keypad activity for 5 minutes the controller returns to LOCKED mode 3 25 Over Speed Limit optional DPG 2201 001 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 gc greater than the highest set speed For example If the highest set speed is 1800 RPM and this parameter is set to 20 then an over speed condition will be detected at 2160 RPM the value that is 20 greater than 1800 Formula 1 20 1800 RPM 2160 RPM Woodward 19 DPG 2201 00X Controllers Manual 36523G T
33. e actuator to return to minimum fuel Features include e lsochronous speed control e Droop operation 0 to 10 of set speed with 1 10 percent resolution 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 e Smoke control on start up e Remote setup e Serial communication port 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 Power Flow Series Gas Valves 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 DPG 2201 00X Controllers Manual 36523G Chapter 2 Controller Specifications The controller s main electrical and mechanical specifications are listed below along with several performance characteristics Electrical Operating Voltage Range 9 30 Vdc Rated Output Current 7 A Maximum continuous Maximum Surge Current 14 A not to exceed ten seconds Input Signal from the Magnetic Pickup Se RMS minimum during All cabling for this unit is limited to less than 30m 98 4 Power cabling is limited to less than 10m 82 8 in total length See wiring diagrams for specific cable types required Mechanical Ambient Operating
34. e 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 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 wit
35. editing is currently 1099 then after pressing the INC key the parameter s new value will be 1100 6 Woodward Manual 36523G DPG 2201 00X Controllers An underflow occurs when the value 00 is displayed and the DEC key is pressed assuming this is not the parameter s minimum value This will cause the displayed value to become 99 while the non displayed value in the parameter s upper 2 digits will be decreased by one You can verify this by pressing both INC and DEC at the same time to view the new value in the upper digits For example If the full 4 digit value of the parameter you are editing is currently 1800 then after pressing the DEC key the parameter s new value will be 1799 When values exceeding 9 999 are to DECIMAL TO HEXADECIMAL be displayed the controller uses the CONVERSION CHART hexadecimal numbering system to Hexadecimal represent the value of the thousands Value Equivalent position A Example 1 The desired set speed is 10 069 Hertz The upper two digits displayed by the controller will be A 0 and the lower 2 digits displayed will be 69 Example 2 The desired set speed is 10 972 Hertz The upper two digits displayed by the controller will be A 9 and the lower 2 digits displayed will be 72 nim goJo Woodward 7 DPG 2201 00X Controllers Manual 36523G Chapter 3 Parameter Reference This chapter provides information regarding each parameter s function Each of this chapter s subsections provid
36. eed optional 13 3 11 Gain Factor reQuired ccccccccssseeccceeeeeeeeeseeeceeeeeeeeesseeeeeesessuaeeeeeees 13 3 12 Speed Filter freoured 14 3 13 Idle Hold Time optional 14 3 14 Accel Rate Optional ccccccsssscccccessseceecssesseeeeseaeeeeesseaseeessssageeees 14 3 19 Decel Rate Optional a AA 15 3 16 Startup Rate optional aaa NAAN 15 Ch ka ter le NA TG GULAT AA a 16 318 Torgu ue Limit e Me EE 16 3 19 Integral Low Limit optional 17 3 20 Integral High Limit optional a 17 3 21 Percent Droop Optional cccccccccseeeeeeeeeeeeseeeeeseeeeeeeesaaeeeeesseeeeees 18 3 22 No Load Calibration optional 18 3 23 Full Load Calibration optonal 18 3 24 Password optional 19 3 25 Over Speed Limit optonal cee ceccccceecesseeseeeeeeesseeeseeeeeeeeessaaaeeees 19 3 26 Set Speed A Min optional 20 3 27 Set Speed A Max optional 20 3 28 Set Speed B Min optional 20 3 29 Set Speed B Max optional 20 3 30 Idle Speed Min optional 20 3 31 Idle Speed Max optional a 21 3 32 Duty Cycle Limit optional 21 3 33 Startup Speed required cccccseeeeecceeeeeeeeeeeeeeeeeeeeeesseeeeeeeessaaeeeeeeees 21 3 34 Startup Duty Cycle optional a 22 CHAPTER 4 UNIVERSAL PST 02x000020002 nna nauuna nauuna wanna unan na nna KKN RK RKN REN RKN KEN 23 Jet OCG UNO BEE 23 AA AA E nes 23 e R
37. eed duration after a long or sustained under speed condition was present The high limit helps reduce the duration and amount of engine over speed by maintaining a maximum actuator position When larger PWM duty cycle values do not increase the engine speed any further but a negative off soeed measured speed less than the target speed remains letting the Integral term grow more positive is not beneficial Unused positive integration would cause a slower recovery from an over speed condition If an engine overload situation causes the engine speed to remain below the target speed for some period of time then the 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 from ever reaching the target speed The first line of defense in reducing overspeed or under speed errors is a well tuned controller via the PID terms Woodward 17 DPG 2201 00X Controllers Manual
38. ement 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 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 engi
39. er 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 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
40. er to a value equal to the exact number of pulses that the MPU delivers to the controller in one revolution of the engine to display set speeds in RPM The formula used to convert the magnetic pickup signal from a Hertz value to a RPM value is M puHe rtz x 60s EngineRPM NumberOfT eth ep For example 3960772 x 60s 1800RPM 132Teeth The following derivation of the above formula can be used to convert from RPM to Hertz EngineRPM d or eeth _ Mpu Hert When the No of Flywheel Teeth parameter is used the SET SPEED A SET SPEED B IDLE SPEED OVER SPEED LIMIT SET SPEED A MIN SET SPEED A MAX i 240 z8 NAAN NM SET SPEED B MIN SET SPEED B MAX IDLE SPEED MIN IDLE SPEED MAX and STARTUP SPEED parameters are displayed as RPM values instead of Hertz values 3 2 Set Speed A required SET SPEED A is the controller s target speed when the SPEED SEL input terminal 8 is open and the startup sequence has completed The startup sequence is complete when the target speed and the engine speed reach the set speed 10 Woodward Manual 36523G DPG 2201 00X Controllers When a two position switch is connected between SPEED SEL and 5 Vdc terminal 13 then an open switch selects SET SPEED A as the controller s target speed If the controller s SPEED SEL input is not used then SET SPEED A is automatically the active target speed after the startup sequence is completed The default v
41. es information about a single parameter Subsection numbering corresponds to the parameter numbering on the controller s label to make it easier to locate information about the parameter of interest For example Parameter 6 PROPORTIONAL is described in subsection 3 6 chapter 3 subsection 6 The following table lists each of the parameters and their default minimum and maximum values Note that several of the parameters have minimum and maximum values set by other parameters Parameters listed in boldface are required settings for the controller Note also that all Speed and Rate values are shown as magnetic pick up Hertz values parameters 2 5 16 18 28 31 34 Changing the No of Flywheel Teeth will cause different default values to be displayed based on the Hertz to RPM formula described in subsection 3 1 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 Parameters marked with an asterisk are IMPORTANT displayed as RPM values when the No of Flywheel Teeth is greater than zero These parameters can be changed with PST max by 100 at once when engine is running 8 Woodward Manual 36523G DPG 2201 00X Controllers Parameter List DPG 2201
42. eter can be set to any value within the range bordered by current Set Speed A setting and 11 000 Hertz or its RPM equivalent 3 28 Set Speed B Min optional Set Speed B Min is used to set the lowest value allowed for adjustments of Set Speed B This parameter can be set to any value within the range bordered by 10 Hertz or its RPM equivalent and the current value of Set Speed B 3 29 Set Speed B Max optional Set Speed B Max is used to set the highest value allowed for adjustments of Set Speed B This parameter can be set to any value within the range bordered by current Set Speed B setting and 11 000 Hertz or its RPM equivalent 3 30 Idle Speed Min optional Idle Speed Min is used to set the lowest value allowed for adjustments of Idle Speed This parameter can be set to any value within the range of 10 Hertz or its RPM equivalent and the current value of Idle Speed 20 Woodward Manual 36523G DPG 2201 00X Controllers 3 31 Idle Speed Max optional ldle Speed Max is used to set the highest value allowed for adjustments of ldle Speed This parameter can be set to any value within the range bordered by current ldle Speed and 11 000 Hertz or its RPM equivalent 3 32 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 Fuel limiting is achieved by setting the maximum duty cycle or o
43. eturn to the selected set speed No Load Calibration is now complete User Interface Select the FULL LOAD CAL parameter Engine speed will return to the selected set speed Universal PST Proceed to Step 6 Now apply full load to the engine and allow the speed to stabilize Assumes the governor was previously tuned User Interface Wait 5 seconds then press the controller s ENTER key to record the calibration value Universal PST Wait 5 seconds then from the Universal PST Status View window enter the value displayed for the Actuator FS in to the Full Load Cal parameter and press ENTER Full load calibration is now complete Remove the load from the engine The engine speed will increase to the no load droop speed Droop calibration is complete Woodward 35 DPG 2201 00X Controllers Manual 36523G After droop calibration the difference between the No Load Cal and Full Load Cal parameter value should be greater than 100 for best operation of droop The droop function may still work for smaller differences but with less accuracy You may be able to get some improvement by modifying or adjusting actuator linkage or adding springs The goal is to achieve a wider range of measured current change through the actuator from no load to full load If the calibrated range is too small then droop may not work at all The actuator position sensing method used by this controller does not work with all actuators A different
44. ge 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 precautions 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 antistatic protective bag it comes in until
45. gine speed reaches the active set speed The active set speed is the Idle Speed if the Idle Hold Time parameter is a nonzero value 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 UseaPC 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 s startup screen press the View Status button then press the Start Monitoring button to begin reading values Woodward 21 DPG 2201 00X Controllers Manual 36523G 3 34 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 over speed 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 a meter to measure the duty cycle across the ACT termina
46. h it the full standard Woodward product warranty Woodward Product and Service Warranty 5 01 1205 This option 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 45 DPG 2201 00X Controllers Manual 36523G 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 TI CE handling read and observe the precautions in Woodward manual 82715 Guide for Handling and Protection of Electronic Controls Printed Circuit Boards and Modules Replac
47. he default value of 100 is used to disable over speed detection Use values less than 100 to enable the over speed limit function and set the limit speed to 1 overspeed limit value 100 highest set speed DPG 2201 002 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 an RPM value depending on whether the No of Flywheel Teeth parameter is zero or nonzero respectively The default value of 15 000 Hertz 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 NOTE for DPG 2201 002 MODELS When the No of Flywheel Teeth parameter is used the OVER SPEED LIMIT parameter is displayed in RPM values instead of Hertz values The controller must be turned off to clear N O TI C E the over speed detection before the engine can be restarted 3 26 Set Speed A Min optional Set Speed A Min is used to set the lowest value allowed for adjustments of Set Speed A This parameter can be set to any value within the range bordered by 10 Hertz or its RPM equivalent and the current value of Set Speed A 3 27 Set Speed A Max optional Set Speed A Max is used to set the highest value allowed for adjustments of Set Speed A This param
48. i yd werd LL U 1500 1000 500 0 Data File C _Woodward Apps Universa PST v3 MPU_DA Pause Chart Data Reset View Table WOODWARD 0KO 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 Charts 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 Tables button to set the display mode back to Table View e Select items from the menu Data File C Program Files Woodwar Universal PS TSMPL_ 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 27 DPG 2201 00X Controllers Universal PST Menu Items Use the File menu to e Open a previously saved setup data file e Save setup data to a file e Send setup data to the default printer e Exit the program Manual 36523G pe Universal PST version 3 0 0 File view Port Help Open a setu
49. ified NOTICE Not applicable for the following parameters o No of Flywheel Teeth while engine is running o Droop o No Load Calibration while not in Droop calibration procedure o Full Load Calibration e Decimal point not blinking The selected parameter s value cannot be modified parameter editing is locked and values can only be viewed This is the case when password protection is active and the unlock code has not been entered Read about the Password parameter in the Parameter Reference chapter for more information about using password protection e Right digits decimal point is blinking or ON The lower two digits the tens digit and the ones digit of a parameter s 4 digit value are being displayed e Left dote decimal point is ON The upper two digits the thousands digit and the hundreds digit of a parameter s 4 digit value are being displayed The upper two digits of a parameter are always view only and can never be modified directly The upper two digits change when the lower digits overflow transition from 99 to 00 or underflow transition from 00 to 99 PARAMETER EDIT MODE The value of the selected parameter is displayed A blinking decimal point means the value can be modified otherwise the value Is view only INC key Increase the selected parameter s value LED Display DEC key Decrease the selected parameter s value Return to PARAMETER SELECT MODE SELECT key and ignore changes made to the para
50. 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 30 Woodward Manual 36523G DPG 2201 00X 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_DATAO0 csv is the default file name used to save engine 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 If 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
51. ize of the controller output response to a step change in the speed error Saturation a higher Proportional value Increases output response to a step change in error a lower Proportional value Decreases output response to a step Change in error Proportional response Controller output Saturation O o Error 96 3 6 Integral required The integral term is one of the interrelated PID terms that determine how well a DPG 2201 00X 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 Note Integral is needed to eliminate speed offsets due to proportional gain and should never be left at zero Integral response to constant error arger Integral value smaller Integral value Controller output 6 12 Woodward Manual 36523G DPG 2201 00X Controllers 3 7 Derivative required The derivative term is one of the interrelated PID terms that determine how well a DPG 2201 00X controller governs the engine s speed The derivative responds to the rate of change in the speed error This parameter is primarily used to dam
52. les 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 31 DPG 2201 00X Controllers Manual 36523G Chapter 5 Calibration Instructions ECO eS See eS Basic Adjustments The controller is programmed at the factory with default 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 need to adjust the parameters shown in the table and install a switch or jumper between SPEED S
53. ls of the controller while the engine is running Note To determine if your meter is reading the correct value a First apply power to the controller but do NOT start the engine b Second measure the duty cycle across the ACT terminals 3 and 4 The reading should be 5 for 5 If the reading is 95 then reverse the leads 2 Usea 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 s startup screen press the View Status button then press the Start Monitoring button to begin reading values 22 Woodward Manual 36523G DPG 2201 00X Controllers Chapter 4 Universal PST 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 contr
54. meter s value ENTER Save the parameter s new value and return to PARAMETER SELECT MODE INC amp DEC Use to display the upper digits of values Simultaneously larger than 99 4 Woodward Manual 36523G DPG 2201 00X Controllers Keypad The keypad consists of four pushbuttons named ENTER SELECT INC and DEC ENTER Key The ENTER key is used to exit PARAMETER EDIT MODE and return to PARAMETER SELECT MODE while saving the parameter s new value to nonvolatile memory Nonvolatile memory is where parameter values are stored so that they are remembered even when the controller is not being powered In PARAMETER SELECT MODE pressing the ENTER key displays the version number of the controller s programming SELECT Key The SELECT key is used to enter PARAMETER EDIT MODE from PARAMETER SELECT MODE once a particular parameter has been selected for editing The SELECT key is also used to escape from PARAMETER EDIT MODE and return to PARAMETER SELECT MODE without saving a change ina parameter s value The value a parameter had when PARAMETER EDIT MODE was entered is restored INC increase Key The INC key is used to increase the displayed value In PARAMETER SELECT MODE each press of the INC key will cause the next higher parameter identification number to be displayed When the maximum parameter identification number is reached the next INC key press will cause the first parameter ID number to be displayed For example
55. neers 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 www woodward com support 46 Woodward Manual 36523G How to Contact Woodward DPG 2201 00X Controllers 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 PHONE NUMBER 55 19 3708 4800 86 512 6762 6727 FACILITY Germany Kempen 49 0 21 52 14 51 Stuttgart 49 711 78954 0 91 129 4097100 81 43 213 2191 82 51 636 7080 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 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 Poland 48 12 295 13 00 United States 1 970 482 5811 United States 1 970 482 5811 You can also contact the Woodward Customer Service Department or consult our worldwide directory www woodward com support directory cfm fo
56. ng and Protection of Electronic 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 36523G DPG 2201 00X Controllers Contents aa ey ELECTROSTATIC DISCHARGE AWARENESS csscsscsecnecneenseneeneeneensesneneeneees V CHAPTER 1 GENERAL INFORMATION kx ENNER ENNEN E NENNEN KEREN EK KEREN KKK KKK 1 Ji ONG NO NEE 1 CHAPTER 2 CONTROLLER SPECIFICATIONS ccccccccssssseeneeeeeeeceensseneeeeesenenees 2 User Ite aCe Ope Call ON EE 3 Operaing leie EE 3 sabe AA AA T 5 LED DED I e ANAN AA DAANAN AA 6 CHAPTER 3 PARAMETER REFERENCE 02 02x02000002a KREE naasa asaan KK EK KEREN KKK KKK 8 Param ter E 9 3 1 No of Flywheel Teeth optional 10 3 2 Set Speed A required aa 10 3 3 Set Speed B Optional aa 11 3 4 Idle Speed optional a 11 3 5 Proportional reoumred 12 3 6 Integral Reen EE 12 3 7 Derivative required a 13 3 8 OVG Set Speed A required aa 13 3 9 OVG Set Speed B 0optional m 13 3 10 OVG Idle Sp
57. ngue Lea UI Ou STI del 18 Inbegral Law H i i 99 20 Integral High dl IR Hardware 1 Mme Stalas H M Write All gibain all ow Chart WOODWARD TAN 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 Alls 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 26 Woodward Manual 36523G DPG 2201 00X Controllers e 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 Software 30 View Chart CHART VIEW PST Yersion 3 0 0 x File view Port Help Vertical Scale Horizontal Scale in seconds Oto 12000 Hz ais C 60 c 30 2 100 5 T Tuning View C o to 6000 Hz A eae 0 0 Chart Recorder Signal Filtering Cvt Wa et 1000 Hz Min OCCCOCO Max at Integral 50 12000 TO nn a a Derivative 25 Sea Ir OVE Set Speed i 20 Wa III TI OVG Set SpeedB 20 gek OVE Idle Speed 20 8000 L Speed Filter 16 Ton II Startup Lint 1000 o D a A Integral Low 0 Zee ie 4000 Sai TI ee 5 TT
58. niversal 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 A universal version wa BABKBKTTA KH TH AMA x Eie Wew Pol Hel DPG 2201 Parameter Setup Soe Ham Wahoo Deal Hummel Maca Hame Vahm Dolau Mirren Aasa 1 Number af Teeth H i i n 1 Bperat Ding H i n 100 2 Set Speed A CO II 10 Loni 2 Ho Load Cal DI m0 A Sel Speed H TUO TEUD TI 11000 3 Full Load Cal TAO TU u Timo 4 Idle Speed 500 500 LI NOD 24 Parimad oO j F m Hrmgo onal din Zi 1 YI 24 Uvex Speed Les 100 100 U UU R Intro full full il 99 8 Set Speed A kin In in in III T Deten t 25 25 F 27 Gei Speed A H NOOD ir limo 11000 E UYG amp Sel Speed A il Al 1 D 24 Sed Speed H Mm TU 1u Tu Tia 3 NYE Set Spred A 20 A 1 Di 29 Set Spend A Hang 11000 11000 Cu 1100 10 OVG Idle Speed KU 20 F HL Idle Speed Men lo 1d 1d Sall 11 Gain tarieor Fili di 1 YY 41 Idle Speed May TI TTUN II TIO l2 Speed Filter IG IG z4 32 Duty Cycle Luma 95 de 10 y5 13 Idle Hold Tuo H l U 3793 33 Slarlup Speed TUD TG Tu 11000 14 Accel Aate ima III 1 iini H Startup Diy Cyel H H F Di 15 Decel Mate limo limo l IOO0 16 Slarlup Rate TUD TUI 1 OI 17 Startup Limit Tmo SIN J II la To
59. 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 WR DPG 2201 SIGNAL CONNECTS TO No connection nc PC receive RxD Transmit data to PC DB9 pin 2 PC transmit TxD Receive data from PC DB9 pin 3 PC common Da CN DB9 pin 5 5 Vdc Do NOT connect at bag PC end No connection RJ11M 654321 Remote access via the COMM port is intended for connection only while programming tuning and IM POR TA N T troubleshooting the control engine It is a service port and not intended for permanent connection of a PC and or cable Woodward 25 DPG 2201 00X Controllers Manual 36523G 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 ls the correct COMM Por selected Is the UFG powered After the problem is found and corrected you can either restart U
60. ntime 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 When changing Duty Cycle Limit parameter it is IM P OR TA N T recommended to update Integral High Limit parameter ETE as well to value less or equal Duty Cycle Limit value 3 33 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 Speed Set Speed A or Set Speed B before the engine has started Therefore when the engine does start it may over speed 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 controller considers the startup sequence complete Typically the startup sequence ends when the en
61. oller s COMM port to your computer s serial port during service and initial programming Features Universal PST features include e Automatic 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 controllers 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 23 DPG 2201 00X Controllers Manual 36523G Acquiring Universal PST The Universal PST software can be downloaded from the Woodward website If you also require connection h
62. on 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 Status View The Status View panel is displayed only after pressing Name Value the lt View Status gt button The Status View panel is part Sin of the Table View display mode as Keypad The Status View panel displays a table where each row ahi shows the Name of a read only parameter and its Speed Diff current Value when Auto Read is ON Press left mouse click the lt START Monitoring gt button to have the Universal PST program automatically oa refresh the Values Press the lt STOP Monitoring gt button STARS Hawa to disable automatic refresh Auto Road is OLT E Woodward 29 DPG 2201 00X Controllers Manual 36523G 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
63. one similar Click the Save button and choose a folder to save the download to File Download x e Some files can harm tour computer If the file information below hee looks suspicious or you do not fully trust the source do not open or save this file File name UniversalP5T NEW exe File oe Application From IAAL Wood wand com KA This type of file could harm pour computer if it contains malicious code Would you like to open the file or save it to your computer Open Cancel More Info kg Always ask before opening this type of file 24 Woodward Manual 36523G DPG 2201 00X Controllers 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 Installing Universal PST After downloading the software file from the Woodward web site run it and follow the installer instructions IMPORTANT The installation 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 cannot 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
64. or 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 Woodward 13 DPG 2201 00X Controllers Manual 36523G 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 these oscillations will have lower amplitude With mo
65. p data File Save setup data to a File Print setup data Value Default lh o o 3736 1000 Use the View menu to e Select Parameter Table view Table Ab Universal PST Yersion 3 0 0 View File view Pork Help vw Parameter Table e Select Chart Recorder view Chart Chart Recorder rameter Setu View Name Value Default L 0 0 1 Number of Teeth Use the Port menu to e Select the PC s serial port that is connected to the DPG 2201 00X A Universal PST Yersion 3 0 0 File View Port Help vw LOM DPC come CO iCOM4 Value Default l o 0 1 Number of Teeth Use the Help menu to access e Help on the Universal PST for DPG e Help on the DPG 2201 00X that is currently in communication with the PC e Information about the Universal PST for DPG application pi 1 Number About 2 Set Spee pe Universal PST Yersion 3 0 0 File View Port Help Setup Tool Help DPG 22 Governor Help Contents Parameter Definitions Parameter Setup The Parameter Setup panel displays a table where each row shows the Name of a user programmable parameter its current 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 modifie
66. peed has been tracking the target speed and has reached SET SPEED A 34 Woodward Manual 36523G DPG 2201 00X Controllers Droop Calibration Procedure To use Droop a calibration sequence must be done first On DPG 2201 001 Models the calibration sequence can be done only by using the controller s built in user interface On DPG 2201 002 Models the calibration sequence can be done by using either the controller s built in user interface or Universal PST Calibration Sequence Make sure the engine is running at the selected set speed and the governor is tuned User Interface Universal PST Enter a value of 41 into the Password parameter to allow editing of the droop related parameters User Interface Select the DROOP parameter and adjust its value while the engine is running with no load applied Universal PST While the engine is running with no load applied enter a value for the desired percentage of droop in to the Percent Droop parameter and press ENTER Engine speed will increase to selected set speed 1000 value of Yo DROOP 1000 User Interface Allow the engine to stabilize at the no load droop speed then press the controller s ENTER key to set the percent droop Universal PST Allow the engine to stabilize at the no load droop speed From the Universal PST Status View window enter the value displayed for the Actuator FS in to the No Load Cal parameter and press ENTER The engine speed will r
67. pen 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 to minimize or eliminate overshoot A zero value is allowed but systems typically require some derivative gain to improve overall engine speed control Derivative response to changes in the rate of deceleration or the rate of acceleration Q o 2 el _ KO o 5 Cc O O The error is sampled at regular intervals When the Rate of change changes red dot the Derivative s impact on controller output changes 3 8 OVG Set Speed A required This overall gain acts as the multiplier on the three PID terms proportional integral and derivative when Set Speed A is selected as the active target speed This gain term is adjustable from 01 to 99 3 9 OVG Set Speed B optional This overall gain acts as the multiplier on the three PID terms proportional integral and derivative when Set Speed B is selected as the active target speed This gain term is adjustable from 01 to 99 3 10 OVG Idle Speed optional This 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 startup when the idle hold timer is running This gain term is adjustable from 01 to 99 3 11 Gain Fact
68. plemented 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 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 iv Woodward Manual 36523G DPG 2201 00X Controllers Electrostatic Dischar
69. r the name of your nearest Woodward distributor or service facility 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 Your Name Site Location Phone Number Fax Number Engine Turbine Model Number Manufacturer Number of Cylinders if applicable Type of Fuel gas gaseous steam etc Rating Application Control Governor 1 Woodward Part Number amp Rev Letter Control Description or Governor Type Serial Number Control Governor 2 Woodward Part Number amp Rev Letter Control Description or Governor Type Serial Number Control Governor 3 Woodward Part Number amp Rev 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 47 We appreciate your comments about the content of our publications Send comments to icinfo woodward com Please reference publication 36523 MW 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 thro
70. re 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 Typically the value 24 works well on small 3 or 4 cylinder engines A value of 16 is recommended for 6 or 8 cylinder engines The following formula can also be used to derive a good starting point for the speed filter value for a given engine application Round the result to the nearest integer The maximum value allowed is 24 No of flywheel teeth No of engine cylinders 0 75 speed filter value 3 13 Idle Hold Time optional The idle hold time specifies how long after starting the engine is to stay at the idle speed before finishing the ramp to the target speed The time value has a resolution of one tenth of a second During the 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 speed SET SPEED A or SET SPEED B 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 con
71. s that may be coupled to the power bus Parallel inductive loads still need to be suppressed because pulses from unsuppressed parallel loads may 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 the 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 40 Woodward Manual 36523G DPG 2201 00X Controllers Chapter 7 Diagnostics amp Troubleshooting Display Codes om Controller memory failure Replace controller PERO Loss of remote speed potentiometer signal Overspeed detected Controller must be turned off and reset to allow an engine restart Actuator drive overcurrent detected Check wiring Check actuator loading Woodward 41 DPG 2201 00X Controllers Manual 36523G Troubleshooting Table SYMPTOM REMEDY BAT and BAT leads are reversed Check wiring Battery voltage too low Should measure between 9 and 30 VDC Controller is defective Replace it LED Display Does No
72. stem 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 switched unsuppressed inductive loads 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 be disconnected and a 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 39 DPG 2201 00X Controllers Manual 36523G DPG control Optional o bro o Optional Optional Switched source iu 043 peo saijonpul Angay Jayjo 10 Jo enjoy aAi onpu 2V buss may use two W
73. t Light Up When Controller Is Powered The parameter s value is the maximum value allowed The parameter s value is the minimum value allowed Unable to Modify Parameters A display code is active Refer to the Display Codes section above Password protection is enabled Enter Password Keypad failure replace unit Actuator leads not connected or shorted No fuel source Turn on fuel source Battery voltage is low Charge or replace the battery Set speed is lower than crank speed Increase the set speed Startup Rate setting is too low The target speed ramps up too slow Engine Does Not Start 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 Increase the Proportional value Increase the appropriate OVG overall gain value Use the Startup Limit Decrease the Startup Ramp Rate Engine Over speeds at Startup Improve PID tuning Integral too low or zero Derivative too low or zero Engine Does Not Reach PID values are too low A tuning that is too soft can prevent the Set Speed controller from delivering the needed actuator drive signal to reach the set speed PID values are too high Tuning is too hot or
74. target speed It is desired that the new speed of 3475 be reached in precisely 1 5 seconds The following formula determines the value needed by Decel Rate to decrease the engine speed from Set Speed A to Set Speed Bin 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_seconds startup_rate_value The controller increases the engine speed from the engine s crank speed to the active target speed at the rate specified The controller will bring the engine to the Idle Speed for the Idle Hold Time then continue increasing the engine speed at the Accel Rate until the engine reaches the selected target speed Set Speed A or Set Speed B Exception 1 In cases where the target speed is less than the Idle Speed and the Idle Hold Time is nonzero the startup ramp sequence
75. the keypad and the display have a unique way of operating The following tables provide a quick reference to the behavior of the display and the function of each key when a particular operating mode is active PARAMETER SELECT MODE is the mode used to select a parameter for viewing and editing This mode is active when the 2 digit value being displayed is blinking The value displayed is a parameter s identification ID number The controller s label lists each user adjustable parameter and its corresponding ID number PARAMETER SELECT MODE The ID number of a parameter listed on the SSE LEN controller s label is blinking on and off INC key Increase the parameter ID number by one DEC key Decrease the parameter ID number by one SELECT key Activate PARAMETER EDIT MODE on the parameter whose number was blinking ENTER Display the version number of the controller s programming INC amp DEC Simultaneously Turn on all LED segments as a test Woodward 3 DPG 2201 00X Controllers Manual 36523G PARAMETER EDIT MODE is the mode that displays the selected parameter s value and allows the value to be modified This mode is active when the 2 digit value displayed is on and no longer blinking The value displayed is the selected parameter s current value The display s decimal points have several different meanings while in PARAMETER EDIT MODE These are described below e Decimal point blinking The selected parameter s value can be mod
76. troller should increase the engine s speed when a new higher target speed is made active The parameter value is specified in MPU magnetic pickup Hz per second based on the following formula higher speed in Hertz lower speed in Hertz2 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 14 Woodward Manual 36523G DPG 2201 00X Controllers 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 engine s speed when a new lower target speed is made active The parameter value is specified in MPU magnetic pickup Hertz per second based on the following formula higher speed in Hertz 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
77. ughout the world Complete address phone fax email information for all locations is available on our website 2010 12 Skokie
78. 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 N O TI CE caused by improper handling read and observe the precautions in Woodward manual 82715 Guide for Handling and Protection of Electronic Controls Printed Circuit Boards and Modules Woodward V Manual 36523G DPG 2201 00X Controllers Chapter 1 General Information Introduction This manual provides information on the following DPG controllers DPG 2201 001 and DPG 2201 002 The DPG 2201 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 all controller features through the built in user interface Properly tuned this controller delivers fast engine response to speed or load changes while providing precise stable isochronous operation Separately programmable Proportional Integral and Derivative gains are provided for tailoring controller response to many engine applications Other adjustments include acceleration and deceleration ramp rates startup and torque limits idle speed and idle hold time This controller can also provide droop speed control with 100 user selectable droop levels The controller s internal FAILSAFE reacts instantly to loss of the engine speed signal allowing th

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