User Manual

DPG-2223-00X
Digital Controllers

Programmable Controllers
for Isochronous Generators with
Load Sharing Capability

Manual 36522F
 This is the safety alert symbol. It is used to alert you to potential personal
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.

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, 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

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

and observe the precautions in Woodward manual 82715, Guide for Handling 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 2009
All Rights Reserved
Manual 36522F DPG-2223-00X Digital Controllers

Contents

REGULATORY COMPLIANCE ...................................................................... III

Declaration of Conformity ...................................................................................... iii
EMC Limitations .................................................................................................... iv
ELECTROSTATIC DISCHARGE AWARENESS ................................................. V
CHAPTER 1. GENERAL INFORMATION .......................................................... 1
Introduction ............................................................................................................ 1
CHAPTER 2. CONTROLLER SPECIFICATIONS ................................................ 2
Electrical ................................................................................................................ 2
Mechanical ............................................................................................................ 2
Performance .......................................................................................................... 2
User Interface Operation ....................................................................................... 3
Operating Modes ........................................................................................... 3
Keypad ........................................................................................................... 4
LED Display ................................................................................................... 6
CHAPTER 3. PARAMETER REFERENCE ........................................................ 7
Parameter List ....................................................................................................... 8
3.1 No. of Flywheel Teeth (optional) ............................................................. 9
3.2 Remote Speed Min (optional) ............................................................... 10
3.3 Remote Speed Max (optional) .............................................................. 10
3.4 Set Speed A (required) ......................................................................... 10
3.5 Idle Speed (optional)............................................................................. 11
3.6 Proportional (required) .......................................................................... 11
3.7 Integral (required) ................................................................................. 11
3.8 Derivative (required) ............................................................................. 12
3.9 OVG @ Remote Speed Min (optional) ................................................. 12
3.10 OVG @ Remote Speed Max (optional) .............................................. 12
3.11 OVG @ Set Speed A (required) ......................................................... 12
3.12 OVG @ Idle Speed (optional) ............................................................. 12
3.13 Gain Factor (required) ........................................................................ 13
3.14 Speed Filter (required) ........................................................................ 13
3.15 Idle Hold Time (optional) .................................................................... 13
3.16 Accel Rate (optional) .......................................................................... 14
3.17 Decel Rate (optional) .......................................................................... 14
3.18 Startup Rate (optional) ....................................................................... 14
3.19 Startup Limit (optional) ....................................................................... 15
3.20 Torque Limit (optional) ........................................................................ 15
3.21 Integral Low Limit (optional) ............................................................... 16
3.22 Integral High Limit (optional) ............................................................... 16
3.23 Percent Droop (optional) .................................................................... 17
3.24 No Load Calibration (optional) ............................................................ 17
3.25 Full Load Calibration (optional) ........................................................... 17
3.26 Password (optional) ............................................................................ 18
3.27 Over Speed Limit (optional) ................................................................ 18
3.28 Set Speed A Min (optional) ................................................................. 19
3.29 Set Speed A Max (optional) ................................................................ 19
3.30 Idle Speed Min (optional) .................................................................... 19
3.31 Idle Speed Max (optional) ................................................................... 19
3.32 Duty Cycle Limit (optional) .................................................................. 19
3.33 E1 Handler Select (optional) ............................................................... 19
3.34 Startup Speed (required) .................................................................... 20
3.35 Startup Duty Cycle (optional) .............................................................. 21
3.36 Speed Pot Action (optional) ................................................................ 21

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CHAPTER 4. UNIVERSAL PST ................................................................... 22

Introduction .......................................................................................................... 22
Features ....................................................................................................... 22
System Requirements ................................................................................. 22
Acquiring Universal PST ...................................................................................... 23
Installing Universal PST............................................................................... 24
Wiring the COMM Port to a PC ................................................................... 24
Communications Error ................................................................................. 25
Universal PST User Interface Overview ...................................................... 25
Universal PST Menu Items .......................................................................... 27
Parameter Setup .......................................................................................... 27
Parameter Help ............................................................................................ 28
Synchronizing Universal PST with a DPG ................................................... 28
Status View .................................................................................................. 28
Tuning View ................................................................................................. 29
Chart Recorder ............................................................................................ 29
Engine Speed Data Collection ..................................................................... 30
CHAPTER 5. CALIBRATION INSTRUCTIONS ................................................. 31
Basic Adjustments ............................................................................................... 31
Tuning Methodology ............................................................................................ 31
Droop Calibration Procedure ............................................................................... 33
Remote Speed Potentiometer Calibration Procedure ......................................... 34
Startup Sequence ................................................................................................ 35
CHAPTER 6. INSTALLATION INSTRUCTIONS ................................................ 36
Terminal Descriptions .......................................................................................... 36
Wiring Diagram .................................................................................................... 37
Centralized Suppression ..................................................................................... 38
CHAPTER 7. DIAGNOSTICS & TROUBLESHOOTING ..................................... 40
Display Codes ..................................................................................................... 40
Troubleshooting Table ......................................................................................... 41
CHAPTER 8. SERVICE OPTIONS ................................................................ 43
Returning Equipment for Repair .......................................................................... 45
Replacement Parts .............................................................................................. 45
Engineering Services ........................................................................................... 46
How to Contact Woodward .................................................................................. 46
Technical Assistance ........................................................................................... 47

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Regulatory Compliance
Declaration of Conformity

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Manual 36522F DPG-2223-00X Digital Controllers

EMC Limitations

Cabling
All cabling for this unit is limited to less than 30m (98.4’). See wiring diagrams for
specific cable types required.
Power cabling is limited to less than 10m (32.8’) in total length from its source;
power is intended to be from a local bus structure. The control is NOT intended
to have a power bus that is derived from a plant-wide distribution system, remote
source, or similar ―mains‖ type distribution systems. The power to the control
should also be a dedicated circuit, directly to the battery or source via a power
and return wire that are routed together.
See User Manual 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 in-
tended usage, as described in this manual, centralized voltage pulse suppression
should be implemented to help protect the control and other components on the
bus. (See Chapter 6: Installation Instructions.)

COMM Port
The COMM port is intended to be a service port, with only temporary connection
during service or initial configuration. The COMM port is susceptible to some
EMC phenomena and possible unintentional battery return currents.

1. Battery return (B-) is also the communication signal common; typically

PCs connect the communication signal’s common to protective earth.
The PC grounding can provide an unintended return path for B- currents.
If B- and the PC are grounded to protective earth, a communication iso-
lator 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 con-
tact 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 orienta-
tion and short cable length may be used to eliminate these issues, de-
pending on the severity of the environment.

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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.

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.

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Manual 36522F DPG-2223-00X Digital Controllers

Chapter 1.
General Information

Introduction
This manual provides information on the following DPG controllers:
DPG-2223-001 and DPG-2223-002.

The DPG-2223-00X 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 change 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 set, and idle hold time.

The 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 or loss of remote speed potentiometer signal.

Features include:
 Automatic calibration of the remote speed potentiometer
 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
APECS Linkage Free Integral Type

Other Models Available:

DPG-2100 Series – for Genset Applications
DPG-2200 Series – for Genset Applications
DPG-2300 Series – for Off-Road Vehicles
DPG-2400 Series – for EFC Valve Applications

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Manual 36522F DPG-2223-00X Digital Controllers

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)
Connections: Terminal strip with 14 terminals
2.0 VAC RMS minimum during
Input Signal from the Magnetic Pickup:
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
-40°F to +185°F (-40°C to +85°C)
Operating Temperature:
Oil, water, and dust resistant via
Sealing: conformal coating and die cast
enclosure
Weight: 12 oz. (341 g)
Connection: 14-terminal Euro-style connector
Suitable for mounting per SAE
Mechanical Vibration
J1455; 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 10 MPU Hertz to 14,000 MPU
Measurement Range: Hertz
500 MPU Hertz to 11,000 MPU
Governing Speed Range:
Hertz
ILS Input Voltage
2.3–2.7 Vdc
Measurement Range:
ILS Input Speed
± 5% around the set speed
Adjustment Range:
Droop Adjustment Range: 0–10% of the set speed
Droop Setting Resolution: Tenths of a percent

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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 inter-
face. The pushbuttons, also called keys, are described in the section named Key-
pad. The LED display is described in the section named LED Display.

Remote access to the controller’s parameter settings is available when the control-
ler’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 PA-
RAMETER 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

The ID number of a parameter listed on the

LED Display
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.

Activate PARAMETER EDIT MODE on the

SELECT key
parameter whose number was blinking.

Display the version number of the control-

ENTER
ler’s programming.
INC & DEC
Turn on all LED segments as a test.
Simultaneously

PARAMETER EDIT MODE is the mode that displays the selected parameter’s val-
ue 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 parame-
ter’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 pass-
word protection is active and the unlock code has not been entered.
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Manual 36522F DPG-2223-00X Digital Controllers
Read about the Password parameter in the Parameter Reference chap-
ter for more information about using password protection.
 Right digit’s 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.
 Left digit’s 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 dis-

played. A blinking decimal point means the
LED Display
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.

Return to PARAMETER SELECT MODE

SELECT key and ignore changes made to the parame-
ter’s value.

Save the parameter’s new value, and re-

ENTER
turn to PARAMETER SELECT MODE.

INC & DEC Use to display the upper digits of values

Simultaneously 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 PARAME-
TER SELECT MODE while saving the parameter’s new value to nonvolatile memo-
ry. Nonvolatile memory is where parameter values are stored so that they are re-
membered even when the controller is not being powered. In PARAMETER SE-
LECT MODE, pressing the ENTER key displays the version number of the control-
ler’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 re-
turn 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.

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Manual 36522F DPG-2223-00X Digital Controllers
In PARAMETER SELECT MODE, each press of the INC key will cause the next
higher parameter identification number to be displayed. When the maximum para-
meter 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 36 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 cur-
rent 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 36 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
36, 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 be-
ing 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 al-
ways 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. Re-
lease the keys to resume displaying the parameter ID number.

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Manual 36522F DPG-2223-00X Digital Controllers

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, PARAME-
TER 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 al-
ways view only so the right decimal point does not blink. Changes to the upper di-
gits 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 (as-
suming 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.

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 Decimal Hexadecimal
represent the value of the thousands Value Equivalent
position. 10 A
11 B
Example 1: The desired set speed is 12 C
10,069 Hertz. The upper two digits
13 D
displayed by the controller will be
14 E
[A.0], and the lower 2 digits displayed
will be [69.]. 15 F

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.].

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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 control-

ler’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.

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Parameter List
DPG-2223-00X

PARAMETER NAME DEFAULT MINIMUM MAXIMUM

-001 0 0 0
1. No. of Flywheel Teeth
-002 0 0 572
2. Remote Speed Min 1000 10 Remote Speed Max
3. Remote Speed Max 1000 Remote Speed Min 11,000
4. Set Speed A 1000 Set Speed A Min Set Speed A Max
5. Idle Speed 500 Idle Speed Min Idle Speed Max
6. Proportional 25 1 99
7. Integral 50 0 99
8. Derivative 25 0 99
9. OVG @ Remote Speed Min 20 1 99
10. OVG @ Remote Speed Max 0 0 99
11. OVG @ Set Speed A 20 1 99
12. OVG @ Idle Speed 20 1 99
13. Gain Factor 20 1 99
14. Speed Filter 16 1 24
15. Idle Hold Time 0 0 9999
16. Accel Rate 1000 1 11000
17. Decel Rate 1000 1 11000
18. Startup Rate 1000 1 11000
19. Startup Limit 1000 0 1000
20. Torque Limit 1000 0 1000
21. Integral Low Limit 0 0 Integral High Limit
22. Integral High Limit 99 Integral Low Limit 99
23. % Droop 0 0 100
24. No Load Cal 0 0 1000
25. Full Load Cal 1000 0 1000
26. Password 0 0 99
-001 100 0 100
27. Over Speed Limit
-002 15000 10 15000
28. Set Speed A Min 10 10 Set Speed A
29. Set Speed A Max 11000 Set Speed A 11000
30. Idle Speed Min 10 10 Idle Speed
31. Idle Speed Max 11000 Idle Speed 11000
32. Duty Cycle Limit 95 10 95
-001 0 0 1
33. E1 Handler Select
-002 0 0 2
34. Startup Speed 1000 10 11000
35. Startup Duty Cycle 30 5 95
36. Speed Pot Action 0 0 1

Parameters 4, 6, 7, 8, 11, 13, 14, and 34 require adjustment, while adjustments to

the other parameters are optional.

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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.

Adjusting the No. of Flywheel Teeth parameter is

prohibited while the engine is running.

The default value of 0 disables Hz to RPM conversions so all set speeds are dis-
played 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:

MpuHertz  60s   EngineRPM 

NumberOfTeeth

For example:

3960Hz   60s   1800RPM 

132Teeth

The following derivation of the above formula can be used to convert from RPM to
Hertz.

EngineRPM   NumberOfTeeth  MpuHertz

60s

When the No. of Flywheel Teeth parameter is used, the

REMOTE SPEED MIN, REMOTE SPEED MAX, SET
SPEED A, AND IDLE SPEED parameters are displayed
as RPM values instead of Hertz values.

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3.2 Remote Speed Min (optional)

REMOTE SPEED MIN is the controller’s minimum target speed when the Remote
Speed Pot is selected. The controller will read the remote speed pot position when
the SPEED SEL input is OPEN and the startup sequence is complete.

The default value for REMOTE SPEED MIN is 1000 MPU Hertz. The adjustable
range for REMOTE SPEED MIN extends from 10 hertz to Remote Speed Max.

When REMOTE SPEED MIN 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 REMOTE SPEED MIN 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.]

3.3 Remote Speed Max (optional)

REMOTE SPEED MAX is the controller’s maximum target speed when the Remote
Speed Pot is selected. The controller will read the speed pot position when the
SPEED SEL input is OPEN and the startup sequence is complete.

The default value for REMOTE SPEED MAX is 1000 MPU Hertz. The adjustable
range for REMOTE SPEED MAX extends from REMOTE SPEED MIN to 11,000
hertz.

When REMOTE SPEED MAX 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 REMOTE SPEED MAX 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 Set Speed A (required)

SET SPEED A is the controller’s target speed when the SPEED SEL input is at +5
VDC and the startup sequence has completed. The startup sequence is complete
when the target speed and the engine speed reach the set speed.

If the controller’s SPEED SEL input is not used the Remote Speed Pot determines
the controller’s target speed after the startup sequence is completed.

The default value for SET SPEED A is 1000 MPU Hertz. The adjustable range
for SET SPEED A 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 dis-
played by the controller as [A.7] and the lower 2 digits will display [50].

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3.5 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 be
determined by either the Remote Speed Pot position or SET SPEED A depending
on the state of the SPEED SEL input terminal.

The default value for IDLE SPEED is 500 MPU Hertz. The adjustable range for
IDLE SPEED extends from IDLE SPEED MIN and IDLE SPEED MAX.

3.6 Proportional (required)

The proportional term is Saturation
one of the interrelated PID 100% a higher Proportional value
terms that determine how Increases output response to a step
change in error

Controller output (%)

well a DPG-2223-00X con-
a lower Proportional value
troller governs the engine’s Decreases output response to a step
speed. A speed change 50%
Change in error
creates a speed error (the
difference between the tar- Proportional
get speed and the actual response
Saturation
speed.) The proportional
0%
gain controls the size of the
Error (%)
controller output response (-) 0 (+)
to a step change in the
speed error. Each error value produces a unique controller output value

3.7 Integral (required)

The integral term is one of
Integral response to constant error
the interrelated PID terms
100%
Controller output (%)

that determine how well a larger

DPG-2223-00X controller Integral
governs the engine’s value
speed. The integral term smaller
50% Integral
acts to drive speed error to
value
zero. In a proportional only
control with constant load,
there will be a constant 0% Time
speed error that inversely
relates to the proportional
gain of the system. The Error
integral term is key to
Time
isochronous speed control.
This term eliminates the difference between the programmed set speed and the ac-
tual 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.

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3.8 Derivative (required)

The derivative term is one of Derivative response to changes
the interrelated PID terms that 100% in the rate of deceleration or the

Controller output (%)

rate of acceleration.
determine how well a DPG-
2223-00X controller governs
50%
the engine’s speed. The deriv-
ative responds to the rate of
change in the speed error. This 0% Time
parameter is primarily used to
dampen very rapid oscillations (+)
resulting from large speed

Error
changes. The derivative re- 0 Time

sponds to engine acceleration (-)

or deceleration. If the engine
speed approaches the target The error is sampled at regular intervals
speed at a fast rate, the deriva- When the "Rate of change" changes (red dot) the
tive acts to minimize or elimi- Derivative's impact on controller output changes.
nate overshoot. A zero value is
allowed but systems typically require some derivative gain to improve overall engine
speed control.

3.9 OVG @ Remote Speed Min (optional)

This overall gain acts as the multiplier on the three PID terms (proportional, integral,
and derivative) when the Remote Speed Pot is selected to set the active target
speed. This gain term is adjustable from 01 to 99.

This value along with the OVG @ Remote Speed Max value is used to select be-
tween single point gain vs. dual point gain. When OVG @ Remote Speed Max is
zero, the OVG @ Remote Speed Min value is used over the full speed range of the
remote speed pot.

When OVG @ Remote Speed Max is a non-zero value, dual point sloped gain is
used and a new gain value is computed based on the current speed.

3.10 OVG @ Remote Speed Max (optional)

This overall gain acts as the multiplier on the three PID terms (proportional, integral,
and derivative) when the Remote Speed Pot is selected as the active target speed.
This gain term is adjustable from 00 to 99.

When a non-zero value is entered, dual point sloped gain is used and a new gain
value is computed based on the current speed.

3.11 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.

3.12 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.
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3.13 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 ad-
justment 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 equiva-
lent to the previous settings with respect to the controller’s tuning response and now
allow the PID terms to be adjusted higher if needed.

3.14 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 fil-
tering 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 applica-
tion. 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

3.15 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 (REMOTE SPEED POT or SET SPEED
A). The startup sequence is complete once the engine speed reaches the selected
set speed.

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3.16 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

For example, suppose Set Speed A is 3300 Hertz and Remote Speed is at 3960
Hertz. The controller is currently controlling the engine at 3300 Hertz (Set Speed A),
when Remote Speed is selected as the active target speed. It is desired that the
new speed of 3960 be reached in precisely 2 seconds. The following formula de-
termines the value needed by Accel Rate to increase the engine speed from Set
Speed A to Remote Speed in 2 seconds.

[(Remote Speed) – (Set Speed A)] / (N seconds) = accel_rate_value in Hertz per

second

[3960 – 3300] / 2 = 330 Hertz per second

3.17 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 spe-
cified 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 Remote Speed is 3475
Hertz. The controller is currently controlling the engine at 4170 Hertz (Set Speed A),
when Remote Speed becomes the active 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 Remote Speed in 1.5 seconds.

[(Set Speed A) – (Remote Speed)] / (N seconds) = decel_rate_value in Hertz per

second

[4170 – 3475] / 1.5 = 463 Hertz per second

3.18 Startup Rate (optional)

This parameter is used to achieve a smooth controlled engine start. On diesel en-
gines, 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 ac-
tive target speed at the rate specified. The controller will bring the engine to the Idle
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Speed for the Idle Hold Time then continue increasing the engine speed at Accel
rate until the engine reaches the selected target speed (Remote Speed Pot or Set
Speed A).

Exception 1: In cases where the target speed is less then the Idle Speed
and the Idle Hold Time is nonzero, the startup ramp sequence 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
from reaching completion before the engine has even started. The controller con-
siders 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 NUMBER 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 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.

3.19 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 thereby limit-
ing 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 per-
cent of the actuator’s maximum current feedback reading. The controller measures
actuator drive-signal feedback and obtains an approximation of the amperes of cur-
rent 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.

3.20 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 100.0% of available current. Decreasing the value limits
the available drive signal thereby limiting how far open the actuator can go. Increas-
ing 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 actu-
ator 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 normal operation.
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NOTE: If the value is set too low the engine will not be able to carry its rated load.

3.21 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 speed (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 ad-
justed 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.

3.22 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 overspeed duration after a
long or sustained under speed condition was present. The high limit helps reduce
the duration and amount of engine overspeed by maintaining a maximum actuator
position.

When larger PWM duty cycle values do not increase the engine speed any further
but a negative off speed (measured speed less than the target speed) remains, let-
ting the Integral term grow more positive is not beneficial. Unused positive integra-
tion would cause a slower recovery from an overspeed 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 overspeed because it takes time for the integral portion of PID out-
put 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 ad-
justed 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 over speed or under
speed errors is a well-tuned controller via the PID
terms.

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3.23 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 Proce-
dure. See the Calibration Instructions chapter for more information.

Droop mode relies on knowing the actuator position. The actuator’s position corres-
ponds to the amount of fuel being delivered to the engine. The DPG-2223-00X con-
troller senses electrical current flow through the actuator to determine its position.
This method of position sensing does not work with all actuators.

3.24 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 indi-
cates the percentage of electrical current, relative to the measurable maximum, 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 ca-
libration 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 posi-
tion 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.

3.25 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 indi-
cates 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 load
calibration value for proper droop operation. If after performing the Droop Calibra-
tion Procedure the full load calibration value is less than the no load calibration val-
ue then the droop function cannot be used. Some actuators may have a current

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versus position curve that is incompatible with this controller’s method of determin-
ing actuator position.

Note: This parameter is only modified during the Droop Calibration Procedure. See
the Calibration Instructions chapter for more information.

3.26 Password (optional)

The password parameter is provided to protect against inadvertent parameter
changes that may occur whenever the keys are pressed and a parameter modifica-
tion is not intended. The password parameter has three possible settings: DIS-
ABLED, LOCKED, and UNLOCKED

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. When the password protect parameter is selected, the LED display will show
[Pd] for 2 seconds, indicating the password-disabled mode, then the value [00.] is
displayed. The user can then edit the value.

LOCKED – This setting means that password protection is active and only parame-
ter 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. If not already in the UN-
LOCKED mode, the user must get into the UNLOCKED mode in order to enter a 99
to disable password protection.

3.27 Over Speed Limit (optional)

DPG-2223-001 Models:
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 %] 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

The 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-2223-002 Models:
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 a
RPM value depending on whether the Number of Flywheel Teeth parameter is zero
or nonzero respectively. The default value of 15,000 Hertz is used to disable over
speed detection.

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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.

The controller must be turned off to clear the over

speed detection before the engine can be restarted.

3.28 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.

3.29 Set Speed A Max (optional)

Set Speed A Max is used to set the highest value allowed for adjustments of Set
Speed A. This parameter can be set to any value within the range bordered by cur-
rent Set Speed A setting and 11,000 Hertz (or its RPM equivalent).

3.30 Idle Speed Min (optional)

This parameter sets the minimum value that the Idle Speed parameter is allowed to
have. This parameter can be set to any value within the range bordered by 10 Hertz
(or its RPM equivalent) and the current value of Idle Speed.

3.31 Idle Speed Max (optional)

This parameter sets the maximum value that the Idle Speed parameter is allowed to
have. This parameter can be set to any value within the range bordered by current
Idle Speed setting and 11,000 Hertz (or its RPM equivalent).

When the No. of Flywheel Teeth parameter is used, the

SET SPEED A MIN, SET SPEED A MAX, IDLE SPEED
MIN, AND IDLE SPEED MAX parameters are displayed
as RPM values instead of Hertz values.

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 on-time allowed dur-
ing 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%.

3.33 E1 Handler Select (optional)

This parameter’s value determines how the controller will handle the E1 error gen-
erated when a ―Loss of Remote Set Speed Signal‖ is detected. Upon detecting a
―Loss of Remote Set Speed Signal‖ the controller automatically returns to the Re-
mote Speed Min value.

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When the value entered is zero or one, a ―Loss of Remote Set Speed Signal‖ is de-
fined when the measured Remote Speed Signal input voltage is less than 0.20 VDC
or greater than 4.8 VDC.

When the E1 Handler Select parameter value is zero, power must be removed
from the controller to clear the E1 error.

When the E1 Handler Select parameter value is one, the E1 error is automatically
cleared when the Remote Set Speed Signal returns to the Speed Pot Min or Speed
Pot Max position recorded during calibration.

When the E1 Handler Select parameter value is two, the DPG-2223-002 will accept
a 0.0 to + 5 Vdc Remote Speed Signal without detecting a ―Loss of Remote Set
Speed Signal‖ and generating an E1 error.

3.34 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 when-
ever 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 tar-
get speed will be ramped to the active set speed (Idle, Remote Speed, or Set
Speed A) before the engine has started. Therefore, when the engine does start, it
may overspeed or output excessive smoke because the startup ramp, having al-
ready 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 Star-
tup Speed becomes the target speed that the controller must reach before the con-
troller considers the startup sequence complete. Typically, the startup sequence
ends when the engine 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 Remote Speed or Set Speed A).

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 a meter to measure the frequency across the MPU+ and
MPU- terminals of the controller during cranking or . . .
2) Use a PC 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 Moni-
toring button to begin reading values.

When the No. of Flywheel Teeth parameter is used, the

STARTUP SPEED parameter is displayed as a RPM
value instead of Hertz value.

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3.35 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 be-
cause 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 overspeed 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 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 (#3 and #4). The reading should be 5 for
5%. If the reading is 95, then reverse the leads.
2) 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 crank-
ing. Note: from the Universal PST’s startup screen press the View Status
button, then press the Start Monitoring button to begin reading values.

3.36 Speed Pot Action (optional)

The Speed Pot Action parameter affects how the controller interprets the REMOTE
SET SPEED SIG input. When in forward acting mode, as the voltage at the Remote
Set Speed Signal input increases the engine speed increases. When in reverse act-
ing mode, as the voltage at the Remote Set Speed Signal input decreases the en-
gine speed increases. This is shown in the table below.

REMOTE SET SPEED

PEDAL ACTION SETTING DIRECTION
INPUT VOLTAGE
0 = Forward Acting Increase CW
1 = Reverse Acting Decrease CCW

The DPG-2223-00X defaults to forward acting mode.

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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 parame-
ter settings and monitor controller operation. Universal PST also includes a graphi-
cal 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 control-
ler. 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 controller’s COMM port to your com-
puter’s serial port during service and initial programming.

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 file for reuse
 Single button read to get the current values of all parameters
 Single button write to program a DPG with previously saved setup
values
 Engine speed monitoring via a chart recorder to aid in tuning the
controller
 Saving chart recorder data to a Microsoft Excel compatible file
 Help information on each of the controller’s parameters
 Help information on using the Universal PST

System Requirements
Universal PST minimum system requirements:
®
 Pentium 133 MHz PC
 50 MB of hard disk space
 64 MB of RAM
 Display resolution set to SVGA (800x600) or higher
®
 Windows 98se, NT 4.0, 2000, and XP or greater
®
 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.

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Acquiring Universal PST

There are two ways to acquire a copy of the Universal PST application:
 Obtain the DPG Software Calibration Kit
 Download the application from the Woodward website

Obtaining the DPG Software Calibration Kit:

The DPG Software Calibration Kit (Woodward P/N 8447-1003) contains the lat-
est version of Universal PST on CD-ROM, a DB-9 Modular Adapter and mod-
ular cable. Contact the Woodward sales department to request a DPG Software
Calibration Kit for a nominal charge. Telephone: (847) 967-7730.

Downloading Universal PST:

The Universal PST application is also available to download from the Wood-
ward Software Products page at www.woodward.com/IC/Software, Use the ―Se-
lect a Product‖ drop down menu in the center of the web page to select ―DPG-
2xxx digital controllers‖ 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 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] but-
ton and choose a folder to save the download to.

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.
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Installing Universal PST

Instructions to Install from CD-ROM:
When you insert the DPG Software Calibration Kit’s CD-ROM into your com-
puter, the ―autorun‖ file on the CD will attempt to launch the ―setup.exe‖ pro-
gram. If the ―autorun‖ feature is disabled on your computer or does not start the
setup program you can launch the program manually. To start the installation
manually, explore the contents of the CD then double click on the ―setup.exe‖
file.
Instructions to Install from the Downloaded File:
The file downloaded from the Woodward web site contains two files: ―ReadMe-
First.txt‖ and ―setup.exe‖. Run the downloaded file to extract its contents to a
folder you choose on your computer’s hard drive. Then run the ―setup.exe‖ pro-
gram from the folder you extracted it to.

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 not interrupt the installation pro-
gram even though it may appear as
though it is not running.

NOTE: Administrator rights may be needed to install on some Microsoft Win-

dows operating systems (such as Windows XP Professional) for the setup pro-
gram 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 RJ11M
DPG-2223 SIGNAL CONNECTS TO:
POSITION
654321
1 No connection N/C
PC receive (RxD)
2 Transmit data to PC
DB9 pin 2
PC transmit (TxD)
3 Receive data from PC
DB9 pin 3
5 4 3 2 1
PC common
4 COMMON
DB9 pin 5
5 +5 Vdc (Do NOT con- 9 8 7 6
N/C
nect at the PC end) DB9F
6 No connection N/C

Remote access via the COMM port is intended for

connection only while programming, tuning and
troubleshooting the control/engine. It is a service port and
not intended for permanent connection of a PC and/or cable.

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Communications Error
The following message window appears when Universal PST is running and
unable to communicate with a DPG.

After the problem is found and corrected, you can either restart Universal PST
or press the <Read All> button to clear the error message. 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

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 displayed in the Pa-
rameter Setup panel.
 Press the <Write All> button to transmit setup values to the controller.
 Press the <View Status> button to display read only parameters in the
Status View panel.

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 Press the <View Chart> button to set the display mode to Chart View.
 Select items from the menu.

CHART VIEW

In Chart View the user can:

 Monitor engine speed in real-time.
 Adjust the horizontal and vertical scale settings of the chart recorder.
 Edit parameter values related to controller tuning. These same parame-
ters 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 the display mode back to Table
View.
 Select items from the menu.

NOTE: Pressing a button means positioning the mouse pointer over the button
and clicking the left mouse button.

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Universal PST Menu Items

Use the File menu to:
 Open a previously saved setup data file
 Save setup data to a file
 Send setup data to the default printer
 Exit the program

Use the View menu to:

 Select Parameter Table view (Table
View)
 Select Chart Recorder view (Chart
View)

Use the Port menu to:

 Select the PC’s serial port that is con-
nected to the DPG-2000

Use the Help menu to access:

 Help on the Universal PST for DPG
 Help on the DPG-2000 product that is
currently in communication 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 De-
fault, 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 intersec-
tion of the parameter’s row and the Value column. The selected cell will be hig-
hlighted and the value can now be modified. When done modifying the value,
press the computer keyboard’s <Enter> key to transmit the new value to the
controller.

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In the figure shown below, the Set Speed A value has been selected for editing.

Parameter Help
To get help on a particular parameter, single click the left mouse button on a
parameter’s Value, then press <Ctrl><F1> on the computer’s keyboard.
<Ctrl><F1> means press and hold the <Ctrl> key while the <F1> 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 se-
lecting either “Governor Help Contents” or “Parameter Definitions” from the Uni-
versal PST Help menu.

Synchronizing Universal PST with a DPG

Pressing the <Read All> button will load the current values for all of a DPG-
2XXX-00X’s parameters into Universal PST. The <Read All> 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 application is still running,
then the <Read All> button must be pressed in order for Universal PST to syn-
chronize with the new DPG.

The <Write All> button is very useful when reusing saved setup data to confi-
gure a new system with the same data as a previous one. Simply load an ex-
isting 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.

Status View
The Status View panel is displayed only after pressing
the <View Status> button. The Status View panel is part
of the Table View display mode.

The Status View panel displays a table where each row

shows the Name of a read only parameter and its cur-
rent Value (when ―Auto Read is ON‖)

Press (left mouse click) the <START Monitoring> button

to have the Universal PST program automatically refresh
the Values. Press the <STOP Monitoring> button to dis-
able automatic refresh.

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Tuning View
The Tuning View panel is displayed only after pressing the <View Chart> but-
ton. The Tuning View panel is part of the Chart View display mode.

To modify a tuning 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 col-
umn.

The selected cell will be highlighted and

the value can now be modified. When
done modifying the value, press the com-
puter keyboard’s <Enter> key to transmit
the new value to the controller.

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.

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 on the
target speed and center it in the chart recorder. This is most useful dur-
ing 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 da-
ta. 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 meas-
ured by the DPG.

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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_DATA00.csv is the default file name used to save engine speed informa-
tion. You can change the file name by using the <Data File => 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 create a line chart of the data.

IMPORTANT: Do not open data files in another program that are currently be-
ing used by Universal PST. Also be sure to close any open data files needed by
Universal PST before starting it.

The <Data File => 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 au-
tomatically 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 fi-
lename00.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 da-
ta 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 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 <Data Reset> button indicates how
full the complete set of data files is. A total of one million data points (approx-
imately 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 <Data File => button to create a
new base file name in which to receive additional engine speed information.

The <Pause Chart> button stops chart recorder and Data File updates. After
pressing this button the <Continue> button is displayed. Press the <Continue>
button to turn the chart recorder back on and continue recording engine speed
data to the current target file.

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 col-
lected needs to be saved. The active data file is automatically reset each time
the Chart View display mode becomes active.

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Chapter 5.
Calibration Instructions
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 SEL 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.

No. Parameter Name Default Value

4 SET SPEED A 1000
6 PROPORTIONAL 25
7 INTEGRAL 50
8 DERIVATIVE 25
11 OVG @ SET SPEED A 20
13 GAIN FACTOR (note 1) 20
14 SPEED FILTER (note 2) 16
34 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-cylinder engines.

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 0.
2. Set the overall gain low (<20).
3. Increase the proportional term until you get continuous oscillations
greater than 2 Hz.
4. 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.
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.

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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 tran-
sition. START WITH SMALL LOADS.

Note that without integral, a speed error may persist after a load-on load-off transi-
tion. 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
The Proportional
in the amount of error
term's output is
unique for each
+E measured error
Error

0 Time

-E

Integration works on
the sum of the errors
accumulated over time

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Droop Calibration Procedure

To use Droop, a calibration sequence must be done first.
DPG-2223-001 Models
The calibration sequence can be done only using the controller’s built-in user
interface.
DPG-2223-002 Models
The calibration sequence can be done using either the controller’s built-in user
interface or Universal PST.

Make sure the engine is running at the selected set speed and the
Step 1
governor is tuned.
User Interface/ Universal PST: Enter a value of 41 into the Password
Step 2
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
Step 3 value for the desired percentage of droop in to the "Percent Droop" para-
meter and press ENTER.

Engine speed will increase to:

[(selected_set_speed) / ((1000 - value_of_%_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.
Step 4 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 return 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.
Step 5
Universal PST: Proceed to Step 6.
Now apply full load to the engine and allow the speed to stabilize.
Step 6
(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
Step 7
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
Step 8
no load droop speed. Droop calibration is complete.

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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 po-
sition sensing method used by this controller does not work with all actuators. A
different actuator may be required or a different system solution altogether may be
needed by your application, such as an actuator with a position feedback potenti-
ometer and a supporting controller.

Remote Speed Potentiometer Calibration Procedure

To use a Remote Speed Pot, a calibration sequence must be done first. The calibration
sequence can be done using either the controllers built-in user interface or Universal
PST.

Connect a potentiometer to the governor. Refer to wiring diagram in

Step 1
Chapter 6.
Make sure the engine is NOT running and the Remote Speed Pot is se-
Step 2
lected to set the target speed (SPEED SEL is at + 5 Vdc).

Step 3 Adjust the speed pot to the desired counterclockwise (CCW) position.

User Interface/ Universal PST: Enter a value of 69 into the Password

Step 4 parameter to enable the speed pot calibration. The LED will display C0
to indicate that calibration mode is active.
Adjust the speed pot to the desired clockwise (CW) position and back to
Step 5
the counterclockwise (CCW) position.
User Interface: Press the controller’s ENTER key to record the calibra-
tion values. Remote speed pot calibration is complete.
Step 6
Universal PST: Enter a value of 69 into the Password parameter to
record the calibration values. Remote speed pot calibration is complete.

After remote speed potentiometer calibration, the governor uses the learned range
to compute the speed potentiometer’s actual position over the speed range defined
by the Remote Speed Min and Remote Speed Max parameters.

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Startup Sequence

The following example describes the DPG-2223-00X startup sequence.

Startup Sequence Example

A B C D E

3500

3000
IDLE HOLD
SET SPEED A = 3500 Hz
TIME = 100
2500
Speed in Hert z

IDLE SPEED = 1500 Hz

2000

ACCEL RATE = 500 Hz/sec

1500
STARTUP RATE = 250 Hz/sec

1000

STARTUP SPEED = 500 Hz

500

0
0 5 10 15 20 25 30 35 40

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 speed has been tracking the target speed and
has reached SET SPEED A.

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Chapter 6.
Installation Instructions
The DPG-2223-00X 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 mounted on the engine or in an environment
that exceeds the mechanical specifications outlined in Chapter 2. The controller
should be mounted in a position to allow access to the user interface, the COMM
port and the terminal strip.

Terminal Descriptions

NO. NAME FUNCTION

1 BAT+ Battery positive (9–30 Vdc)

2 BAT- Battery negative
3 ACT Actuator drive output (7 A max continuous)
4 ACT Actuator drive return
5 MPU+ Magnetic pickup signal input
6 MPU- Magnetic pickup ground
7 SHIELD Ground connection for cable shielding

8 SPEED SEL Digital input used to select the target set speed
Supply voltage for the digital input. Optional
9 +5 Vdc
ILS reference
10 ILS SIGNAL ILS input used to adjust speed +/- 5%

11 ILS REF (2.5 V) Supply voltage around which ILS operates

12 Remote Speed Pot COM Common for the remote speed pot CCW
Remote Speed Signal Input Voltage Range
E1 Handler Mode 0: (0.20 to 4.80 Vdc)
13 Remote Speed Pot SIG
E1 Handler Mode 1: (0.20 to 4.80 Vdc)
E1 Handler Mode 2: (0.00 to 5.00 Vdc)

14 Remote Speed Pot + 5 V Supply voltage for the remote speed pot CW

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.

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Wiring Diagram

Cabling for DPG 2233-00X controllers is limited to

less than 30m (98.4’). Power cabling is limited to less
than 10m (32.8’) in total length. The wiring diagram
below shows specific cable types required.

Dimensions are in inches. [Dimensions in brackets are millimeters.]

Figure 1. Wiring Diagram for DPG-2223-00X Models

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Centralized Suppression
The control meets the regulatory requirements for its intended installations, and
when installed correctly as directed, the DPG input power can handle some level
of surge pulses.

Because the control power input is designed to be connected to a local bus and to
have inductive load kickbacks suppressed, it cannot withstand a charging system
load dump, heavy inductive kickbacks, or heavy surge pulses.

1. Charging system load dump is a pulse created when a heavily charging

battery that is being charged by an alternator or generator (or similar), is
disconnected from the bus.
2. Inductive kickbacks are due to series or parallel switched, unsuppressed,
inductive loads switched ON and OFF wired on the same power bus.
3. Large surge pulses are typically due to indirect lightning strikes. Some
surge pulses may also be present due to series inductances with switched
currents.

The EMC environment into which the control is installed may have the above
conditions if the control is installed OUTSIDE its intended usage. If the stated
conditions exist, centralized pulse suppression should be implemented to
protect the components on the bus, including the control.

Figure 2 is an example of centralized suppression that should be implemented at

the system level when any of the following are present:

1. The battery can be disconnected and an unsupressed high current

battery charging system is in use.
2. Unsuppressed, switched inductive loads are in parallel or series with
the control power.
3. The input power is derived from a distribution system or it is more than
32.8’ (10m) from the control to the main power source.

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Manual 36522F DPG-2223-00X Digital Controllers

Actuator
Make/Brake contact may DPG Control

Alternator / Generator / AC to DC Charger

cause Surge Pulses

Actuator or other heavy inductive load

Local Bus (Large & Short Length)
Optional
Switched source

Application, Poor Practice)

Application, Poor Practice)

Long Cable (Unintended

Long Cable (Unintended

Inductive load suppression -

(WGC p/n 1682-1059).

(WGC p/n 1682-1061).

24V buss may use two

12V buss may use two

buss suppressed centrally

May not be needed if
15KP17CA parts

15KP13CA parts.
Battery

Local Bus (Large & Short Length)

Discrete parts are available from V47ZA7 MOV to

Woodward as: chassis at the control
12V: 8923-1271.KIT (24V & 12V system,
24V: 8923-1272.KIT WGC p/n 1688-411)

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 depend on the full system
implementation.
Examples:
(a) Two 15KP17CA and V47ZA7 through-hole parts are available from
Woodward as 8923-1272.KIT. This kit is for a 24V system. It will sup-
press alternator load dump from alternators within the 200A range, as
well as indirect lightning pulses that may be coupled to the power bus.
Parallel inductive loads still need to be suppressed because pulses
from unsuppressed parallel loads will be clamped at voltages too high
to protect the control.
(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.
Please see Application Note 51319 for more details.

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Manual 36522F DPG-2223-00X Digital Controllers

Chapter 7.
Diagnostics & Troubleshooting

Display Codes

CODE MEANING

E0 Controller memory failure. Replace controller.

E1 Loss of remote speed potentiometer signal.

Overspeed detected. Controller must be turned off

E2
and reset to allow an engine restart.

Actuator drive overcurrent detected. Check wiring.

E3
Check actuator loading.

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Manual 36522F DPG-2223-00X Digital Controllers

Troubleshooting Table

SYMPTOM REMEDY

LED Display Does Not BAT + and BAT – leads are reversed. Check wiring.
Light Up When Controller Battery voltage too low. Should measure between 9 and 30 Vdc
Is Powered Controller is defective. Replace it.
The parameter’s value is the maximum value allowed.
The parameter’s value is the minimum value allowed.
Unable to Modify
A display code is active. Refer to the Display Codes section above.
Parameters
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.
Engine Overspeeds Increase the appropriate OVG (overall gain) value.
at Startup Use the Startup Limit.
Decrease the Startup Ramp Rate.
Improve PID tuning.
Integral too low or zero
Derivative too low or zero
PID values are too low. A tuning that is too soft can prevent the control-
ler from delivering the needed actuator drive signal to reach the set
speed.
Engine Does Not Reach
Set Speed PID values are too high. Tuning is too hot or 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.
Integral Low Limit setting is too high. Return the value to the default
setting of zero.
Integral High Limit setting is too low. Return the value to the default
setting of 99.
Improve PID tuning.
Integral setting is too low.
Engine Takes Too Long to
Startup Rate setting is too low.
Reach Set Speed
Accel Rate setting is too low.
Speed Filter setting is too high.

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Manual 36522F DPG-2223-00X Digital 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 A PID value or an OVG value is too high.
Speed 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.
Excessive Smoke at Startup
Use a lower Startup Limit setting.
Low MPU signal voltage. It should read 2.0 VRMS minimum.
Gain too low.
Sluggish Response to
Improve PID tuning.
Load Changes
Speed filter setting is too high.
Improve PID tuning.
Engine Instability With Speed filter setting is too low.
No Load Fuel is restricted. Check actuator linkage.
Battery voltage is too low.
Improve PID tuning.
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
Load Sharing Does Not Work between 2.300 and 2.700 Vdc.
Use shielded wiring.
No Load and Full Load values are not calibrated. Perform Droop
Calibration Procedure.
Droop Does Not Work
Difference between No Load and Full Load calibration values is
too small. Should be > 100 for best performance.

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Manual 36522F DPG-2223-00X Digital Controllers

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:
 Consult the troubleshooting guide in the manual.
 Contact the manufacturer or packager of your system.
 Contact the Woodward Full Service Distributor serving your area.
 Contact Woodward technical assistance (see ―How to Contact Woodward‖
later in this chapter) and discuss your problem. In many cases, your problem
can be resolved over the phone. If not, you can select 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:
 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.
 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 Recognized Engine Retrofitter (RER) is an independent company that
does retrofits and upgrades on reciprocating gas engines and dual-fuel
conversions, and can provide the full line of Woodward systems and
components for the retrofits and overhauls, emission compliance upgrades,
long term service contracts, emergency repairs, etc.
 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.

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Manual 36522F DPG-2223-00X Digital 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:
 Replacement/Exchange (24-hour service)
 Flat Rate Repair
 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 available 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 with it the full standard Woodward product warranty (Woodward
Product and Service Warranty 5-01-1205). This option is applicable to mechanical
products only.

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Manual 36522F DPG-2223-00X Digital Controllers

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 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.

Packing a Control
Use the following materials when returning a complete control:
 protective caps on any connectors;
 antistatic protective bags on all electronic modules;
 packing materials that will not damage the surface of the unit;
 at least 100 mm (4 inches) of tightly packed, industry-approved packing
material;
 a packing carton with double walls;
 a strong tape around the outside of the carton for increased strength.

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.

Replacement Parts
When ordering replacement parts for controls, 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.

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Manual 36522F DPG-2223-00X Digital Controllers

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
 Product Training
 Field Service

Technical Support is available from your equipment system supplier, your local Full-
Service Distributor, or from many of Woodward’s worldwide locations, depending upon
the product and application. This service can assist you with technical questions or
problem solving during the normal business hours of the Woodward location you
contact. Emergency assistance is also available during non-business hours by phoning
Woodward and stating the urgency of your problem.

Product Training is available as standard classes at many of our worldwide

locations. We also offer customized classes, which can be tailored to your needs
and can be held at one of our locations or at your site. This training, conducted by
experienced personnel, will assure that you will be able to maintain system reliability
and availability.

Field Service engineering on-site support is available, depending on the product

and location, from many of our worldwide locations or from one of our Full-Service
Distributors. The field engineers are experienced both on Woodward products as
well as on much of the non-Woodward equipment with which our products interface.

For information on these services, please contact us via telephone, email us, or use
our website and reference www.woodward.com/support, and then Customer
Support.
How to Contact Woodward
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 Engine Systems Turbine Systems

FACILITY PHONE NUMBER FACILITY PHONE NUMBER FACILITY PHONE NUMBER
Brazil ------------- +55 (19) 3708 4800 Brazil ------------- +55 (19) 3708 4800 Brazil ------------- +55 (19) 3708 4800
China ------------+86 (512) 6762 6727 China ------------+86 (512) 6762 6727 China ------------+86 (512) 6762 6727
Germany: Germany:
Kempen --- +49 (0) 21 52 14 51
Stuttgart ----- +49 (711) 78954-0 Stuttgart ----- +49 (711) 78954-0
India --------------- +91 (129) 4097100 India --------------- +91 (129) 4097100 India --------------- +91 (129) 4097100
Japan -------------- +81 (43) 213-2191 Japan -------------- +81 (43) 213-2191 Japan -------------- +81 (43) 213-2191
Korea--------------- +82 (51) 636-7080 Korea--------------- +82 (51) 636-7080 Korea--------------- +82 (51) 636-7080
The Netherlands - +31 (23) 5661111 The Netherlands - +31 (23) 5661111
Poland -------------- +48 12 618 92 00
United States----- +1 (970) 482-5811 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 on Woodward’s website (www.woodward.com/support) for
the name of your nearest Woodward distributor or service facility.
For the most current product support and contact information, please refer to the
latest version of publication 51337 at www.woodward.com/publications.

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 Manual 36522F DPG-2223-00X Digital Controllers

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:

General
Your Name
Site Location
Phone Number
Fax Number

Prime Mover Information

Engine/Turbine Model Number
Manufacturer
Number of Cylinders (if applicable)
Type of Fuel (gas, 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 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.

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Manual 36522F DPG-2223-00X Digital Controllers

Woodward 48
 We appreciate your comments about the content of our publications.
Send comments to: icinfo@woodward.com

Please reference publication 36522.

PO Box 1519, Fort Collins 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.

2010/1/Skokie