Woodward DPG-2201-00 Series User manual

User Manual
DPG-2201-00X
Digital Controllers
APECS
®Programmable Controllers
for Isochronous Generators with
Load Sharing Capability
Manual 36523B

WARNING
Read this entire manual and all other publications pertaining to the work to be
performed before installing, operating, or servicing this equipment. Practice all
plant and safety instructions and precautions. Failure to follow instructions can
cause personal injury and/or property damage.
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.
CAUTION
To prevent damage to a control system that uses an alternator or battery-charging
device, make sure the charging device is turned off before disconnecting the
battery from the system.
In systems where large inductive loads are switched on the DC power buss, surge
impulse energy will be present due to the switching. To address surge energy
affects on the control, appropriate suppression devices must 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 (except antistatic versions) around
printed circuit boards.
• Do not touch the components or conductors on a printed circuit board with
your hands or with conductive devices.
IMPORTANT DEFINITIONS
WARNING—indicates a potentially hazardous situation which, if not avoided, could
result in death or serious injury.
CAUTION—indicates a potentially hazardous situation which, if not avoided, could
result in damage to equipment.
NOTE—provides other helpful information that does not fall under the warning or
caution categories.
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 2005
All Rights Reserved

Manual 36523B DPG-2201-00X Digital Controllers
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Contents
R EGULATORY C OMPLIANCE ...................................................................... III
E LECTROSTATIC D ISCHARGE A WARENESS ................................................ IV
C HAPTER 1. G ENERAL I NFORMATION ..........................................................1
Introduction............................................................................................................ 1
C HAPTER 2. C ONTROLLER S PECIFICATIONS ................................................2
Electrical ................................................................................................................ 2
Mechanical ............................................................................................................ 2
Performance .......................................................................................................... 2
User Interface Operation ....................................................................................... 3
Operating Modes ........................................................................................... 3
Keypad........................................................................................................... 4
LED Display................................................................................................... 6
C HAPTER 3. P ARAMETER R EFERENCE ........................................................8
DPG-2201-00X Parameter List ............................................................................. 9
3.1 No. of Flywheel Teeth (optional)........................................................... 10
3.2 Set Speed A (required)......................................................................... 10
3.3 Set Speed B (optional) ......................................................................... 11
3.4 Idle Speed (optional)............................................................................. 11
3.5 Proportional (required).......................................................................... 12
3.6 Integral (required) ................................................................................. 12
3.7 Derivative (required) ............................................................................. 13
3.8 OVG @ Set Speed A (required) ........................................................... 13
3.9 OVG @ Set Speed B (optional)............................................................ 13
3.10 OVG @ Idle Speed (optional)............................................................. 13
3.11 Gain Factor (required) ........................................................................ 13
3.12 Speed Filter (required)........................................................................ 14
3.13 Idle Hold Time (optional) .................................................................... 14
3.14 Accel Rate (optional) .......................................................................... 14
3.15 Decel Rate (optional).......................................................................... 15
3.16 Startup Rate (optional) ....................................................................... 15
3.17 Startup Limit (optional) ....................................................................... 16
3.18 Torque Limit (optional)........................................................................ 16
3.19 Integral Low Limit (optional)........................................................... 17
3.20 Integral High Limit (optional)............................................................... 17
3.21 Percent Droop (optional) .................................................................... 18
3.22 No Load Calibration (optional)............................................................ 18
3.23 Full Load Calibration (optional)........................................................... 18
3.24 Password (optional)............................................................................ 19
3.25 Over Speed Limit (optional)................................................................ 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)................................................................... 20
3.32 Duty Cycle Limit (optional).................................................................. 20
3.33 Startup Speed (optional)..................................................................... 21
3.34 Startup Duty Cycle (optional).............................................................. 22

Manual 36523B DPG-2201-00X Digital Controllers
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C HAPTER 4. U NIVERSAL PST...................................................................23
Introduction .................................................................................................. 23
Features....................................................................................................... 23
System Requirements ................................................................................. 23
Acquiring Universal PST.............................................................................. 24
Installing Universal PST............................................................................... 25
Wiring the COMM Port to a PC ................................................................... 25
Communications Error................................................................................. 26
Universal PST User Interface Overview...................................................... 26
Universal PST Menu Items.......................................................................... 28
Parameter Setup.......................................................................................... 28
Parameter Help............................................................................................ 29
Synchronizing Universal PST with a DPG................................................... 29
Status View.................................................................................................. 29
Tuning View ................................................................................................. 30
Chart Recorder ............................................................................................ 30
Engine Speed Data Collection..................................................................... 31
C HAPTER 5. C ALIBRATION I NSTRUCTIONS .................................................32
Basic Adjustments ............................................................................................... 32
Tuning Methodology............................................................................................ 32
Droop Calibration Procedure............................................................................... 33
C HAPTER 6. I NSTALLATION I NSTRUCTIONS ................................................35
Terminal Descriptions.......................................................................................... 35
Recommended Mounting .................................................................................... 35
Wiring Diagram.................................................................................................... 36
DPG-2201-001 & DPG-2201-002................................................................ 36
C HAPTER 7. D IAGNOSTICS & T ROUBLESHOOTING .....................................37
Display Codes ..................................................................................................... 37
Troubleshooting Table......................................................................................... 37
C HAPTER 8. S ERVICE O PTIONS ................................................................39
Product Service Options...................................................................................... 39
Replacement/Exchange............................................................................... 39
Flat Rate Repair........................................................................................... 40
Flat Rate Remanufacture............................................................................. 40
Returning Equipment for Repair.......................................................................... 40
Packing a Control ........................................................................................ 40
Return Authorization Number ...................................................................... 41
Replacement Parts .............................................................................................. 41
How to Contact Woodward.................................................................................. 41
Engineering Services........................................................................................... 42
Technical Assistance........................................................................................... 43

Manual 36523B DPG-2201-00X Digital Controllers
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Regulatory Compliance
European Compliance for CE Marking
EMC Directive
Declared to 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 this unit 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.

Manual 36523B DPG-2201-00X Digital Controllers
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Electrostatic Discharge Awareness
All electronic equipment is static-sensitive, some components more than others.
To protect these components from static damage, you must take special
precautions to minimize or eliminate electrostatic discharges.
Follow these precautions when working with or near the control.
1. Before doing maintenance on the electronic control, discharge the static
electricity on your body to ground by touching and holding a grounded metal
object (pipes, cabinets, equipment, etc.).
2. Avoid the build-up of static electricity on your body by not wearing clothing
made of synthetic materials. Wear cotton or cotton-blend materials as much
as possible because these do not store static electric charges as much as
synthetics.
3. Keep plastic, vinyl, and Styrofoam materials (such as plastic or Styrofoam
cups, cup holders, cigarette packages, cellophane wrappers, vinyl books or
folders, plastic bottles, and plastic ash trays) away from the control, the
modules, and the work area as much as possible.
4. Do not remove the printed circuit board (PCB) from the control cabinet
unless absolutely necessary. If you must remove the PCB from the control
cabinet, follow these precautions:
•Do not touch any part of the PCB except the edges.
•Do not touch the electrical conductors, the connectors, or the
components with conductive devices or with your hands.
•When replacing a PCB, keep the new PCB in the plastic anti-static
protective bag it comes in until you are ready to install it. Immediately
after removing the old PCB from the control cabinet, place it in the anti-
static protective bag.
CAUTION
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.

Manual 36523B DPG-2201-00X Digital Controllers
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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, alllowing the actuator to return to minimum fuel.
Features include:
• Isochronous speed control
• Droop operation: 0 to 10% of set speed with 1/10 percent resolution
• User friendly / operator adjustable
• Precision frequency control: 0.25%
• Superior temperature stability
• Reverse battery protection
• Input voltage range: 9–30 Vdc
• Smoke control on start up
• Remote setup
• Serial communication port
Actuator Compatibility:
DYNA 2000 DYNA 7000 DYNA 8000 APECS 0150
DYNA 2500 DYNA 70025 DYNA 8200 APECS 0250
DYNA 10141 DYNA 8400 APECS 0300
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

Manual 36523B DPG-2201-00X Digital Controllers
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Chapter 2.
Controller Specifications
The controller’s main electrical and mechanical specifications are listed here
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)
Connections: Terminal strip with 13 terminals
Input Signal from the Magnetic Pickup: 2.0 VAC RMS minimum during
cranking
(*) All cabling for this unit is limited to less than 30m (98.4’).
Power cabling is limited to less than 10m (32.8’) in total length.
See wiring diagrams for specific cable types required.
Mechanical
Ambient Operating Temperature: -40°F to +185°F (-40°C to +85°C)
Sealing: Oil, water, and dust resistant via
conformal coating and die cast
enclosure
Weight: 12 oz. (341 g)
Connections: 13-terminal Euro-style connector
Mechanical Vibration: Suitable for mounting per SAE
J1455; 1 to 500 Hz, 5G amplitude
Performance
Temperature Stability 0.007 Hz @ 158ºF (70°C)
Steady State Speed Band: ± 0.25% over ambient operating
temperature range
Engine Speed Measurement Range: 10 MPU Hertz to 14,000 MPU
Hertz
Governing Speed Range: 500 MPU Hertz to 11,000 MPU
Hertz
ILS Input Voltage Measurement Range: 2.375
– 2.625 Vdc
ILS Input Speed Adjust Range: ±3% around the set speed
Droop Adjustment Range: 0 to 10 percent of the set speed
Droop Setting Resolution: Tenths of a percent

Manual 36523B DPG-2201-00X Digital Controllers
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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, 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
LED Display The ID number of a parameter listed on the
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 & DEC
Simultaneously Turn on all LED segments as a test
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.
• Decimal point blinking
The selected parameter’s value can be modified.
• 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

Manual 36523B DPG-2201-00X Digital Controllers
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Reference chapter for more information about using password
protection.
• Right digit’s decimal point is blinking or ON
T he lower two digits (the tens digit and the ones digit) of a
parameter’s 4-digit value are being displayed.
• Left digit’s decimal point is ON
T he 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
LED Display
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.
DEC key Decrease the selected parameter’s value.
SELECT key Return to PARAMETER SELECT MODE
and ignore changes made to the
parameter’s value
ENTER Save the parameter’s new value, and
return to PARAMETER SELECT MODE
INC & DEC
Simultaneously Use to display the upper digits of values
larger than 99
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 in a 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.

Manual 36523B DPG-2201-00X Digital Controllers
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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: If the controller’s label lists 34 parameters, then pressing the
INC key when the display is blinking the value 34 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 controller’s 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 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.

Manual 36523B DPG-2201-00X Digital Controllers
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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.
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 digit’s 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 editing is currently 1099, then after
pressing the INC key the parameter’s new value will be 1100.

Manual 36523B DPG-2201-00X Digital Controllers
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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
be displayed, the controller uses the
hexadecimal numbering system to
represent the value of the thousands
position.
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.].
Decimal to Hexadecimal
Conversion Chart
Decimal
Value Hexadecimal Equivalent
10 A
11 B
12 C
13 D
14 E
15 F

Manual 36523B DPG-2201-00X Digital Controllers
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Chapter 3.
Parameter Reference
This chapter provides information regarding each parameter’s function. Each of
this chapter’s subsections provides 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 5. PROPORTIONAL is described in subsection
3.5 (chapter 3 subsection 5).
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 2-4, 14-16, 26-31, 33). 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 below.

Manual 36523B DPG-2201-00X Digital Controllers
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DPG-2201-00X Parameter List
PARAMETER NAME DEFAULT MINIMUM MAXIMUM
-001 0 0 0
1. No. Of Flywheel Teeth -002 0 0 572
2. Set Speed A 1000 Set Speed A
Min
Set Speed A
Max
3. Set Speed B 1000 Set Speed B
Min Set Speed B Max
4. Idle Speed 500 Idle Speed
Min Idle Speed Max
5. Proportional 25 1 99
6. Integral 50 0 99
7. Derivative 25 0 99
8. OVG @ Set Speed A 20 1 99
9. OVG @ Set Speed B 20 1 99
10. OVG @ Idle Speed 20 1 99
11. Gain Factor 20 1 99
12. Speed Filter 16 1 24
13. Idle Hold Time 0 0 9999
14. Accel Rate 1000 1 11000
15. Decel Rate 1000 1 11000
16. Startup Rate 1000 1 11000
17. Startup Limit 1000 0 1000
18. Torque Limit 1000 0 1000
19. Integral Low Limit 0 0 Integral High
Limit
20. Integral High Limit 99 Integral Low
Limit 99
21. % Droop 0 0 100
22. No Load Cal 0 0 1000
23. Full Load Cal 1000 0 1000
24. Password 0 0 99
-001 100 0 100
25. Over Speed Limit -002 15000 0 15000
26. Set Speed A Min 10 10 Set Speed A
27. Set Speed A Max 11000 Set Speed A 11000
28. Set Speed B Min 10 10 Set Speed A
29. Set Speed B Max 11000 Set Speed B 11000
30. Idle Speed Min 10 10 Idle Speed
31. Idle Speed Max 11000 Idle Speed 11000
32. Duty Cycle Limit 95 10 95
33. Startup Speed 1000 10 11000
34. Startup Duty Cycle 30 5 95
Parameters 2, 5, 6, 7, 8, 11 and 12 require adjustment, while adjustments to the
other parameters are optional.

Manual 36523B DPG-2201-00X Digital Controllers
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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.
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 parameter 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:
(
)
(
)
[
]
[ ] [ ]
EngineRPM
ethNumberOfTe
sMpuHertz =
×
60
For example:
The following derivation of the above formula can be used to convert from RPM to
Hertz.
(
)
(
)
[
]
[ ] [ ]
MpuHertz
s
ethNumberOfTeEngineRPM =
×
60
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.
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 value 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].
(
)
(
)
[
]
[ ] [ ]
RPM
Teeth
sHz 1800
132
603960 =
×

Manual 36523B DPG-2201-00X Digital Controllers
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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] 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].
NOTE—When the No. of Flywheel Teeth parameter is used, the SET
SPEED A, SET SPEED B, and IDLE SPEED parameters are displayed
as RPM values instead of Hertz values.

Manual 36523B DPG-2201-00X Digital Controllers
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100%
0%
50%
Integral response to constant error
Time
Time
Error
larger
Integral
value
smaller
Integral
value
Controller output (%)
Error (%)
0 (+) (-)
Controller output (%)
100%
0%
50%
Each error value produces a unique controller output value
Saturation
Saturation
Proportional
response
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
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 size of the controller output response to a step
change in the speed error.
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.

Manual 36523B DPG-2201-00X Digital Controllers
Woodward 13
100%
0%
50%
Derivative response to changes
in the rate of deceleration or the
rate of acceleration.
Time
Time
Error
0
(+)
(-)
The error is sampled at regular intervals
Controller output (%)
When the "Rate of change" changes (red dot) the
Derivative's impact on controller output changes.
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 dampen
very rapid oscillations resulting from large speed changes. The derivative
responds to engine acceleration or deceleration. If the engine speed approaches
the target speed at a fast rate, the derivative acts to minimize or eliminate
overshoot. A zero value is allowed but systems typically require some derivative
gain to improve overall engine speed control.
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 Factor (required)
The gain factor parameter is used to obtain more range of adjustment from the
PID terms. In other words, if any of the PID terms or the overall gain terms reach
their adjustment limits then this value can be modified to provide for more range of
adjustment in the PID and OVG terms.

Manual 36523B DPG-2201-00X Digital Controllers
Woodward 14
For example, if the PID terms are set to 90, 80, and 50 respectively and the Gain
Factor is set to 20, then doubling the Gain Factor by setting it to 40 allows the PID
terms to be halved to 45, 40, and 25 respectively. These new settings are
equivalent to the previous settings with respect to the controller’s tuning response
and now allow the PID terms to be adjusted higher if needed.
3.12 Speed Filter (required)
This parameter indicates the number of flywheel teeth to use when computing an
average engine speed and is used to dampen out speed measurement variations
that can make PID tuning difficult. But, keep in mind the following.
• 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.
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 more cylinders, there is less time
for the speed to slow down before the next cylinder firing.
Rotational mass also affects the amount of speed signal filtering needed. The
more rotational mass, the less filtering is needed. The less rotational mass, the
more filtering is needed.
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
STARTUP 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 controller 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_Hertz)] / (ramp_time_in_seconds) =
accel_rate_value