Woodward APECS DPG-2101-001 User Manual Download Page 1

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User Manual

DPG-2101-001 DPG-2145-001

DPG-21XX-00X

Digital Controllers

APECS

Programmable Controllers for

Isochronous Generators

Manual 36526A

Summary of Contents for APECS DPG-2101-001

Page 1: ...User Manual DPG 2101 001 DPG 2145 001 DPG 21XX 00X Digital Controllers APECS Programmable Controllers for Isochronous Generators Manual 36526A ...

Page 2: ...st be installed in the DC power buss prior to the control s power connection Electronic controls contain static sensitive parts Observe the following precautions to prevent damage to these parts Discharge body static before handling the control with power to the control turned off contact a grounded surface and maintain contact while handling the control Avoid all plastic vinyl and Styrofoam excep...

Page 3: ...al 10 3 4 Idle Speed optional 10 3 5 Proportional required 11 3 6 Integral required 11 3 7 Derivative required 11 3 8 OVG Set Speed A required 12 3 9 OVG Set Speed B optional 12 3 10 OVG Idle Speed optional 12 3 11 Gain Factor required 12 3 12 Speed Filter required 12 3 13 Idle Hold Time optional 13 3 14 Accel Rate optional 13 3 15 Decel Rate optional 13 3 16 Startup Rate optional 14 3 17 Integral...

Page 4: ...STRUCTIONS 28 Basic Adjustments 28 Tuning Methodology 28 CHAPTER 6 INSTALLATION INSTRUCTIONS 30 Recommended Mounting 30 Terminal Descriptions 30 DPG 2101 00X 30 DPG 2111 00X 30 DPG 2145 00X 31 DPG 2146 00X 31 DPG 2155 00X 31 Wiring Diagrams 32 DPG 2101 00X 32 DPG 2111 00X 33 DPG 2145 00X 34 DPG 2146 00X 35 DPG 2155 00X 36 CHAPTER 7 DIAGNOSTICS TROUBLESHOOTING 37 LED Indications 37 Troubleshooting ...

Page 5: ...89 336 EEC COUNCIL DIRECTIVE of 03 May 1989 on the approximation of the laws of the Member States relating to electromagnetic compatibility EMC Limitations All cabling for these controllers is limited to less than 30m 98 4 Power cabling is limited to less than 10m 32 8 in total length See plant wiring diagrams for specific cable types required ...

Page 6: ...terials such as plastic or Styrofoam cups cup holders cigarette packages cellophane wrappers vinyl books or folders plastic bottles and plastic ash trays away from the control the modules and the work area as much as possible 4 Do not remove the printed circuit board PCB from the control cabinet unless absolutely necessary If you must remove the PCB from the control cabinet follow these precaution...

Page 7: ...vided for tailoring controller response to many engine applications Other adjustments include acceleration and deceleration ramp rates idle speed set hold time and more Properly tuned this controller delivers fast engine response to speed or load change while providing precise stable isochronous operation The controller s internal FAILSAFE reacts instantly to loss of the engine speed signal allowi...

Page 8: ... DPG 2155 00X 2 idle Electrical Operating Voltage Range 9 30 Vdc Rated Output Current 7 A Maximum continuous Maximum Surge Current 14 A not to exceed ten seconds Connections Terminal strip with 7 Euro style terminals or a quick connector with 12 pins Input Signal from Magnetic Pickup 2 0 VAC RMS minimum during cranking Input Signal from Engine s Ignition System 40 V minimum during cranking All cab...

Page 9: ...ot available on DPG 2111 00X The DPG 21XX 00X provides two buttons for adjusting the engine set speed INC increases the selected Set Speed A or B DEC decreases the selected Set Speed A or B Gain Potentiometer The DPG 21XX 00X series controllers provide a potentiometer labeled GAIN to adjust the OVG Set Speed A This is one of the controller s tuning parameters DPG 2101 00X DPG 2145 00X DPG 2146 00X...

Page 10: ...ere is an engine speed signal at the controller s tachometer inputs When the LED is on and not blinking it indicates the following 1 The unit is powered 2 There is a controller fault NOTE The slow blink rate Hertz the LED is turned on for 1 second followed by off for 1 second then on again and so on The fast blink rate is 3 times faster than the slow blink rate COMM Port All adjustments require th...

Page 11: ... following chapter is required to make adjustments to the parameters described in this chapter with the exception of Set Speed A Set Speed B and OVG Set Speed A It contains 29 subsections Each subsection provides information about a single parameter The following tables list each of the parameters and their default minimum and maximum values Several of the parameters have minimum and maximum value...

Page 12: ...tartup Rate 1000 3000 1 9999 Opt 17 Integral Low Limit 0 0 Integral High Limit Opt 18 Integral High Limit 99 Integral Low Limit 99 Opt 19 Password 0 0 99 001 100 0 100 Opt 20 Over Speed Limit 002 15000 450 0 15000 450 Opt 21 Set Speed A Min 10 2 10 2 Set Speed A Opt 22 Set Speed A Max 11000 300 Set Speed A 11000 300 23 Not Available 24 Not Available Opt 25 Idle Speed Min 10 2 10 2 Idle Speed Opt 2...

Page 13: ...1000 3000 1 9999 Opt 17 Integral Low Limit 0 0 Integral High Limit Opt 18 Integral High Limit 99 Integral Low Limit 99 Opt 19 Password 0 0 99 001 100 0 100 Opt 20 Over Speed Limit 002 15000 450 0 15000 450 Opt 21 Set Speed A Min 10 2 10 2 Set Speed A Opt 22 Set Speed A Max 11000 300 Set Speed A 11000 300 Opt 23 Set Speed B Min 10 2 10 2 Set Speed A Opt 24 Set Speed B Max 11000 300 Set Speed B 1100...

Page 14: ...eed Filter 16 1 24 Opt 13 Idle Hold Time 0 0 9999 Opt 14 Accel Rate 1000 1 9999 Opt 15 Decel Rate 1000 1 9999 Opt 16 Startup Rate 1000 1 9999 Opt 17 Integral Low Limit 0 0 Integral High Limit Opt 18 Integral High Limit 99 Integral Low Limit 99 Opt 19 Password 0 0 99 001 100 0 100 Opt 20 Over Speed Limit 002 15000 0 15000 Opt 21 Set Speed A Min 10 10 Set Speed A Opt 22 Set Speed A Max 11000 Set Spe...

Page 15: ...he above formula can be used to convert from RPM to Hertz Hertz s rev per Pulses EngineRPM 60 _ _ DPG 2101 00X DPG 2111 00X and DPG 2155 00X Models To use this parameter correctly on controllers sensing engine speed with a magnetic pickup you must know the exact number of flywheel teeth that pass by the magnetic pickup in one revolution of the engine DPG 2145 00X and DPG 2146 00X Models To use thi...

Page 16: ...and SET SPD 2 pin 6 of the connector are tied together In other words when a two position switch is connected between SET SPD 1 pin 12 and SET SPD 2 pin 6 then a closed switch selects SET SPEED B as the controller s target speed The default value for SET SPEED B is 1000 MPU Hertz 25 Hertz ignition The SET SPEED B parameter s adjustable range extends from SET SPEED B MIN to SET SPEED B MAX See the ...

Page 17: ...e speed error 3 6 Integral required The integral term is one of the interrelated PID terms that determine how well a DPG controller governs the engine s speed The integral term acts to drive speed error to zero In a proportional only control with constant load there will be a constant speed error that inversely relates to the proportional gain of the system The integral term is key to isochronous ...

Page 18: ...al 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 overall gain term is adjustable from 01 to 99 3 11 Gain Factor required The gain factor parameter is used to obtain more range of adjustment from the PID ter...

Page 19: ...would be 2 times the number of ignition pulses per one revolution of the engine pulses_per_rev 2 speed_filter_value 3 13 Idle Hold Time optional The idle hold time specifies how long after starting the engine is to stay at the idle speed before finishing the ramp to the target speed The time value has a resolution of one tenth of a second 3 14 Accel Rate optional This rate specifies how fast the c...

Page 20: ... MPU frequencies below the STARTUP SPEED as indicating that the engine is cranking but has not yet started MPU frequencies above the STARTUP SPEED are taken to indicate that the engine has started and the controller will increase the engine speed until the selected set speed is reached Exception In cases where the target speed is less the STARTUP SPEED the startup ramp sequence ends when the targe...

Page 21: ...where reducing the Integral Limit High value can help by preventing excessive windup in the PID output s integration term The integral high limit specifies the PWM duty cycle where the integrator s influence on raising PID output must stop The default value is 99 The value can be adjusted from 99 down to 10 in 1 increments CAUTION Use carefully as improper use can prevent the controller from ever ...

Page 22: ...f to clear the over speed detection before the engine can be restarted 3 21 Set Speed A Min optional Set Speed A Min is used to set the lowest value allowed for Set Speed A adjustments The adjustable range for Set Speed A Min extends from 10 Hertz 2 Hertz ignition to the current value of Set Speed A 3 22 Set Speed A Max optional Set Speed A Max is used to set the highest value allowed for Set Spee...

Page 23: ...p Speed value is set too low less than crank speed the controller s target speed will be ramped to the active set speed Idle Set Speed A or Set Speed B before the engine has started Therefore when the engine does start it may overspeed or output excessive smoke because the startup ramp having already completed no longer controls the rate of engine speed increase If the Startup Speed value is set t...

Page 24: ...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 terminals 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 No 3 an...

Page 25: ...e controller s COMM port to your computer s serial port Features Universal PST features include Automatic configuration to each DPG when communications are established Read write access to all DPG programmable parameters and features View each parameter s default minimum and maximum values Diagnostics utilizing automatic refresh of DPG status Save and open DPG setup data information to and from a ...

Page 26: ...iversal PST The Universal PST application is also available to download from the Woodward Software Products page at www woodward com IC Software Use the Select a Product drop down menu in the center of the web page to select DPG 2xxx digital governors then press the Go button This will automatically redirect you to the Universal PST download page where you can click on the word Download to begin t...

Page 27: ...update your system then you can not use the Universal PST application on this computer Read the setup program s instructions carefully as they appear and respond as needed The installation may take as long as 7 minutes depending on your computer s power and operating system Do not interrupt the installation program even though it may appear as though it is not running NOTE Administrator rights may...

Page 28: ...artup screen Universal PST User Interface Overview Universal PST has two main display modes Table View the main startup screen Chart View TABLE VIEW In Table View the user can View the current values for all user programmable parameters in the Parameter Setup panel Edit a parameter s value by double clicking on a cell in the Value column of the table Press the Read All button to refresh the values...

Page 29: ... 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 Press the Pause Chart button to stop the chart recorder which also stops writing data to the file Press the Continue button to turn the chart recorder back on Press the View Table button to set th...

Page 30: ... with the PC Information about the Universal PST for DPG application 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 ...

Page 31: ...ation cable is unplugged from a DPG and plugged into a different DPG while the Universal PST application is still running then the Read All button must be pressed in order for Universal PST to synchronize with the new DPG 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 p...

Page 32: ...tions The Vertical Scale options provide three different ways to view engine speed data The 0 to 12000 Hz option is the default and sets the vertical axis range to its absolute minimum and maximum measurable values The _____ to ______ Hz option allows you to enter the minimum and maximum speed values to zoom in on a viewing range of interest The 10 of ______ Hz option is primarily used to zoom in ...

Page 33: ...creasing 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 Data Reset button is used to clear out the data collection buffer and overwrite the zero suffixed data coll...

Page 34: ...ller 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 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 th...

Page 35: ... 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 deriv...

Page 36: ...s 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 Terminal Descriptions DPG 2101 00X NO NAME FUNCTION 1 BAT Battery positive 9 30 Vdc 2 BAT Battery negative 3 ACT Actuator drive output 4 ACT Actuator drive return 5 MPU Magnetic pickup signal input 6 MPU Magnetic pickup ground 7 SHIELD Gro...

Page 37: ...pen DPG 2146 00X NO NAME FUNCTION 1 BAT Battery positive 9 30 Vdc 2 BAT Battery negative 3 ACT Actuator drive output 4 ACT Actuator drive return 5 IGN TACH Ignition tachometer signal input 6 IGN GND Ignition ground signal 7 SHIELD Ground connection for cable shielding DPG 2155 00X NO NAME FUNCTION 1 BAT Battery positive 9 30 Vdc 2 ACT Actuator drive output 3 Not Labeled Digital input common 4 INC ...

Page 38: ...length The wiring diagrams below show specific cable types required DPG 2101 00X Dimensions are in inches Dimensions in brackets are millimeters Figure 1 Wiring Diagram for DPG 2101 001 and DPG 2101 002 Controllers 1 Connect the MPU shield at the controller end only Connecting the shield at the MPU source end could introduce noise due to ground loops and also disable the reverse battery protection...

Page 39: ...inches Dimensions in brackets are millimeters Figure 2 Wiring Diagram for DPG 2111 001 Controller 1 Connect the MPU shield at the controller end only Connecting the shield at the MPU source end could introduce noise due to ground loops and also disable the reverse battery protection feature ...

Page 40: ...mensions in brackets are millimeters Figure 3 Wiring Diagram for DPG 2145 001 and DPG 2145 002 Controllers 1 Connect the MPU shield at the controller end only Connecting the shield at the MPU source end could introduce noise due to ground loops and also disable the reverse battery protection feature ...

Page 41: ...ons are in inches Figure 4 Wiring Diagram for DPG 2146 001 and DPG 2146 002 Controllers 1 Connect the MPU shield at the controller end only Connecting the shield at the MPU source end could introduce noise due to ground loops and also disable the reverse battery protection feature ...

Page 42: ...mensions in brackets are millimeters Figure 5 Wiring Diagram for DPG 2155 001 and DPG 2155 002 Controllers 1 Connect the MPU shield at the controller end only Connecting the shield at the MPU source end could introduce noise due to ground loops and also disable the reverse battery protection feature ...

Page 43: ...ontroller is defective Replace it Unable to Modify Parameters The parameter s value is the maximum value allowed The parameter s value is the minimum value allowed Universal PST not communicating with the controller Keypad failure replace unit Engine Does Not Start Actuator leads not connected or shorted No fuel source Turn on fuel source Battery voltage is low Charge or replace the battery Set sp...

Page 44: ...egral setting is too low Startup Rate setting is too low Accel Rate setting is too low Speed Filter setting is too high Engine Does Not Track Speed Setting Changes Is the LED blinking fast 3 Hz No not sensing speed Is the selected set speed parameter being modified A PID value or a Gain value is too high A PID value is too low or zero Accel Rate is set too low Decel Rate is set too low Sluggish Re...

Page 45: ...e structured program and includes the full standard Woodward product warranty Woodward Product and Service Warranty 5 01 1205 This option allows you to call 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 w...

Page 46: ... be returned to Woodward for repair please contact Woodward in advance to obtain a Return Authorization Number When shipping the item s attach a tag with the following information 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 C...

Page 47: ...ols include the following information the part number s XXXX XXXX that is on the enclosure nameplate the unit serial number which is also on the nameplate How to Contact Woodward In North America use the following address when shipping or corresponding Woodward Governor Company PO Box 1519 1000 East Drake Rd Fort Collins CO 80522 1519 USA Telephone 1 970 482 5811 24 hours a day Toll free Phone in ...

Page 48: ...ct us via telephone email us or use our website and reference Customer Services and then Technical Support Product Training is available at many of our worldwide locations standard classes 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 ...

Page 49: ...s gaseous steam etc Rating Application Control Governor Information Please list all Woodward governors actuators and electronic controls in your system Woodward Part Number and Revision Letter Control Description or Governor Type Serial Number Woodward Part Number and Revision Letter Control Description or Governor Type Serial Number Woodward Part Number and Revision Letter Control Description or ...

Page 50: ...CO 80522 1519 USA 1000 East Drake Road Fort Collins CO 80525 USA Phone 1 970 482 5811 Fax 1 970 498 3058 Email and Website www woodward com Woodward has company owned plants subsidiaries and branches as well as authorized distributors and other authorized service and sales facilities throughout the world Complete address phone fax email information for all locations is available on our website 05 ...

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