Related Manuals for Woodward DPG-21 Series
Summary of Contents for Woodward DPG-21 Series
- Page 1 Released Product Manual 36526 (Revision H, 12/2023) Original Instructions DPG-21XX-00X Digital Controllers Programmable Controllers for Isochronous Generators Installation and Operation Manual...
- Page 2 Revisions— A bold, black line alongside the text identifies changes in this publication since the last revision. Woodward reserves the right to update any portion of this publication at any time. Information provided by Woodward is believed to be correct and reliable. However, no responsibility is assumed by Woodward unless otherwise expressly undertaken.
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Page 3: Table Of Contents
ERVICE PTIONS Product Support Options ..........................38 Product Service Options ..........................38 Returning Equipment for Repair ......................... 39 Replacement Parts ............................40 Engineering Services ..........................40 Contacting Woodward’s Support Organization ................... 40 ........................41 EVISION ISTORY ..........................42 ECLARATIONS Woodward... - Page 4 Figure 6-2. Wiring Diagram for DPG-2145-001 and DPG 2145-002 Controllers ........31 Figure 6-3. Wiring Diagram for DPG-2146-001 and DPG-2146-002 Controllers ........32 Figure 6-4. Wiring Diagram for DPG-2155-001 and DPG-2155-002 Controllers ........33 Figure 6-5. Centralized Suppression Implemented at the System Level ............ 34 Woodward...
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Page 5: Warnings And Notices
Be prepared to make an emergency shutdown when starting the engine, turbine, or other type of prime mover, to protect against runaway or overspeed with possible personal injury, loss of life, or property damage. Start-up Woodward... - Page 6 Released Manual 36526 DPG-21XX-00X Digital Controllers On- and Off-highway Mobile Applications: Unless Woodward's control functions as the supervisory control, customer should install a system totally independent of the prime mover control system that monitors for supervisory control of engine (and takes appropriate...
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Page 7: Electrostatic Discharge Awareness
Do not touch the components or conductors on a printed circuit board with your hands or with conductive devices. To prevent damage to electronic components 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. -
Page 8: Emc Limitations
The input is susceptible to RF noise such as switching transients and transmitter signals coupled into the communication cable. Cable orientation and short cable length may be used to eliminate these issues, depending on the severity of the environment. Woodward... -
Page 9: Chapter 1. General Information
DYNA 2500 DYNA 70025 DYNA 8200 APECS 0250 DYNA 10141 DYNA 8400 APECS 0300 APECS Linkage Free Integral Type Other Models Available: DPG-2100 Series – for Genset Applications DPG-2300 Series – for Off-Road Vehicles DPG-2400 Series – for EFC Applications Woodward... -
Page 10: Chapter 2. Controller Specifications
Power cabling is limited to less than 10m (32.8’) in total length. See wiring diagrams for specific cable types required. Mechanical Ambient Operating Temperature: -40°F to +185°F (-40°C to +85°C) Oil, water, and dust resistant via Sealing: conformal coating and die cast enclosure Weight: 10 oz. (284 g) Woodward... -
Page 11: Performance
A fast blinking LED indicates all of the following: The unit is powered. There is an engine speed signal at the controller’s tachometer inputs. Woodward... - Page 12 The Universal PST is an MS Windows based application available from the Software Products page at www.woodward.com/IC/Software. See Chapter 4 for a description of this tool. The COMM port is intended only for configuration and periodic service. Do not leave a computer and/or COMM cable connected to the COMM port.
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Page 13: Chapter 3. Parameter Reference
COMM port and the Universal PST software. The COMM port is intended only for configuration and periodic service. Do not leave a computer and/or COMM cable connected to the COMM port. Woodward... -
Page 14: Parameter List
Opt. = Parameter use is optional. NA = Parameter is not available. Default, Minimum and Maximum values in parenthesis apply when the controller uses ignition pulses to sense engine speed, which would be the case for a DPG-2146-00X controller. Default, M Woodward... -
Page 15: Parameter List
25. Idle Speed Min 10 (2) 10 (2) Idle Speed Opt. 26. Idle Speed Max 11000 (300) Idle Speed 11000 (300) Opt. 27. Duty Cycle Limit Req. 28. Startup Speed 1000 (25) 10 (2) 11000 (300) Opt. 29. Startup Duty Cycle Woodward... - Page 16 DPG-2145-00X and DPG-2146-00X Models To use this parameter correctly on controllers sensing engine speed via ignition pulses, you must know the exact number of ignition pulses that occur in one revolution of the engine. Woodward...
- Page 17 When the idle hold timer reaches zero, the target speed will be either SET SPEED A or SET SPEED B depending on the state of the SPEED SEL input terminal. The default value for IDLE SPEED is 500 MPU Hertz (20 Hertz ignition). The IDLE SPEED parameter’s adjustable range extends from IDLE SPEED MIN to IDLE SPEED MAX. Woodward...
- Page 18 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. Woodward...
- Page 19 PID tuning difficult. But, keep in mind the following. • Too much filtering will slow down the controller’s response to speed changes. • Too little filtering can make the controller overly sensitive and tuning difficult. Woodward...
- Page 20 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 Woodward...
- Page 21 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 over speed or under speed errors is a well-tuned controller via the PID terms. Woodward...
- Page 22 Hertz ignition) is used to disable over speed detection. The controller detects an over speed condition when it measures an engine speed that exceeds the OVER SPEED LIMIT value. When an over speed is detected the controller’s actuator output signal is set to minimum. Woodward...
- Page 23 If the Startup Speed value is set too high (above the active set speed) then the Startup Speed becomes the target speed that the controller must reach before the it considers the startup sequence complete. Woodward...
- Page 24 Use a PC running the Universal PST application and read the value of the PWM command in the View Status panel when the engine is cranking. Note: from the Universal PST startup screen press the View Status button, then press the Start Monitoring button to begin reading values. Woodward...
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Page 25: Chapter 4. Universal Pst
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. -
Page 26: Installing Universal Pst
This will automatically redirect you to the Universal PST download page where you can click on the word Download to begin the download process. Once you are logged into the Woodward download site you are presented with the File Download dialog box shown below, or one similar. Click the [Save] button and choose a folder to save the download to. -
Page 27: Wiring The Comm Port To A Pc
The <Read All> 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. • Table View (the main startup screen) • Chart View Woodward... - Page 28 Edit parameter values related to controller tuning. These same parameters are also on the main parameter setup table. • Press the <Data File => button to open a file for saving chart recorder data. • Press the <Data Reset> button to start data collection to the open file at the beginning. Woodward...
- Page 29 Select the PC’s serial port that is connected to the DPG-21XX-00X Use the Help menu to access: • Help on the Universal PST for DPG • Help on the DPG-21XX-00X that is currently in communication with the PC • Information about the Universal PST for DPG application Woodward...
- Page 30 The <Write All> 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 <Write All> button. Woodward...
- Page 31 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. Woodward...
- Page 32 Use the <View Table> 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...
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Page 33: Chapter 5. Calibration Instructions
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 Woodward... -
Page 34: Startup Sequence
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. Woodward... - Page 35 2000 Hertz from the IDLE SPEED. Ramping stops at point E when the target speed reaches SET SPEED A. The startup sequence also ends at point E assuming the engine speed has been tracking the target speed and has reached SET SPEED A. Woodward...
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Page 36: Chapter 6. Installation Instructions
Actuator drive return SHIELD Ground connection for cable shielding Digital input to decrease selected set speed (Active when tied to Pin 3) IGN GND Ignition ground signal SET SPD 1 Set Speed A selected when this pin is open Woodward... - Page 37 To prevent damage to the controller, make sure that it is wired in accordance with the wiring instructions and diagrams in this manual. • Do not tin the leads before placing them into the terminals. • Ensure the terminals are tightened properly to secure wires. Woodward...
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Page 38: Wiring Diagrams
Dimensions are in inches. [Dimensions in brackets are millimeters.] Figure 6-1. Wiring Diagram for DPG-2101-001 and DPG-2101-002 Controllers Connect the MPU shield at the controller end only. Connecting the shield at the MPU source end could introduce noise due to ground loops and also disable the reverse. Woodward... -
Page 39: Figure 6-2. Wiring Diagram For Dpg-2145-001 And Dpg 2145-002 Controllers
To prevent damage to the controller, make sure that it is wired in accordance with the wiring instructions and diagrams in this manual. • Do not tin the leads before placing them into the terminals. • Ensure the terminals are tightened properly to secure wires. Woodward... -
Page 40: Figure 6-3. Wiring Diagram For Dpg-2146-001 And Dpg-2146-002 Controllers
Figure 6-3. Wiring Diagram for DPG-2146-001 and DPG-2146-002 Controllers Connect the MPU shield at the controller end only. Connecting the shield at the MPU source end could introduce noise due to ground loops and also disable the reverse battery protection feature. Woodward... -
Page 41: Centralized Suppression
Inductive kickbacks are due to series or parallel switched, unsuppressed, inductive loads switched ON and OFF wired on the same power bus. Large surge pulses are typically due to indirect lightning strikes. Some surge pulses may also be present due to series inductances with switched currents. Woodward... -
Page 42: Figure 6-5. Centralized Suppression Implemented At The System Level
(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. - Page 43 Manual 36526 DPG-21XX-00X Digital Controllers 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.
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Page 44: Chapter 7. Diagnostics & Troubleshooting
If not greater than 5%, then restore all parameter values to factory default settings and crank the engine again. Final target speed must be greater than crank speed before the controller will attempt to drive the actuator open. Woodward... - Page 45 PID values may be too high, causing the controller to overreact and make large, rapid changes in PWM duty Engine Unable to Carry Rated cycle output to the actuator. Load Improve PID tuning. Fuel is restricted. Check actuator linkage. Woodward...
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Page 46: Chapter 8. Product Support And Service Options
• An Authorized Independent Service Facility (AISF) provides authorized service that includes repairs, repair parts, and warranty service on Woodward's behalf. Service (not new unit sales) is an AISF's primary mission. A current list of Woodward Business Partners is available at www.woodward.com/local-partner... -
Page 47: Returning Equipment For Repair
All repair work carries the standard Woodward service warranty (Woodward Product and Service Warranty 5-09-0690) on replaced parts and labor. -
Page 48: Replacement Parts
• 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. • Technical Support •... -
Page 49: Revision History
Released Manual 36526 DPG-21XX-00X Digital Controllers Revision History Changes in Revision H— • Removed EPG actuators from the Actuator Compatibility section in Chapter 1 Woodward... -
Page 50: Declarations
Released Manual 36526 DPG-21XX-00X Digital Controllers Declarations Woodward... - Page 51 Released Manual 36526 DPG-21XX-00X Digital Controllers Woodward...
- Page 52 Email and Website—www.woodward.com Woodward has company-owned plants, subsidiaries, and branches, as well as authorized distributors and other authorized service and sales facilities throughout the world. Complete address / phone / fax / email information for all locations is available on our website.
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