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.
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.
All cabling for this unit is limited to less than 30m (98.4’). See wiring diagrams for
specific cable types required.
Power cabling is limited to less than 10m (32.8’) in total length from its source;
power is intended to be from a local bus structure. The control is NOT intended
to have a power bus that is derived from a plant-wide distribution system, remote
source, or similar ―mains‖ type distribution systems. The power to the control
should also be a dedicated circuit, directly to the battery or source via a power
and return wire that are routed together.
See User Manual 36526 for additional regulatory information, limitations, and
wiring diagrams with specific, required cable types.
Power Bus
The power bus is intended to be a local bus without power line surges and to
have inductive load kickback events suppressed. Therefore, the control’s power
input is not designed to withstand a charging system load dump, heavy inductive
kickbacks, or heavy surge type pulses. If the control is installed outside its
intended usage, as described in this manual, centralized voltage pulse
suppression should be 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
isolator should be used between the PC and the control. Damage to the
PC or control, and/or unintended operation may result from a broken
battery return wire or the parallel path.
2. The pins inside the COMM port plug are susceptible to damage by ESD
discharges, static electricity arcs. Care should be taken not to touch
them with tools or put fingers into the port. Always touch your hand or
tool to a grounded piece of metal (discharge ESD) prior to coming in
contact with the communication port.
3. The input is susceptible to RF noise such as switching transients and
transmitter signals coupled into the communication cable. Cable
orientation and short cable length may be used to eliminate these issues,
depending on the severity of the environment.
Woodward v
Manual 36526F DPG-21XX-00X Digital Controllers
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.
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 antistatic protective bag.
Woodward vi
Manual 36526F DPG-21XX-00X Digital Controllers
Chapter 1.
General Information
Introduction
This manual provides information on the following DPG controllers:
DPG-2101-001 and
DPG-2101-002
The DPG-21XX-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 set speed and gain parameters with the
built-in user interface. The COMM port provides access to all other controller settings,
allowing adaptation to each application during service and initial configuration.
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, idle speed set, hold time, and more.
Properly tuned, this controller delivers fast engine response to speed or load change
while providing precise stable isochronous operation.
The controller’s internal FAILSAFE reacts instantly to loss of the engine speed signal,
allowing the actuator to return to minimum fuel.
Features include:
Isochronous speed control
DPG-2145-001 and
DPG-2145-002
DPG-2146-001 and
DPG-2146-002
DPG-2155-001 and
DPG-2155-002
User friendly / operator adjustable
Precision frequency control
Superior temperature stability
Reverse battery protection
Input voltage range: 9–30 Vdc
Remote setup
Serial communication port
DYNA 2500 DYNA 70025 DYNA 8200 APECS 0250
DYNA 10141 DYNA 8400 APECS 0300
APECS Linkage Free Integral Type
Other Models Available:
DPG-2100 Series – for Genset Applications
DPG-2300 Series – for Off-Road Vehicles
DPG-2400 Series – for EFC Valve Applications
Woodward 1
Manual 36526F DPG-21XX-00X Digital Controllers
Model No.
Connector Style
Options
Speed Sensing
Options
Adj.
Set
Speeds
Remote
Speed
INC and
DEC
7-wire
Euro
12-pin
Molex
Magnetic
Pickup
Ignition
Sense
DPG-2101-00X
* *
1 + idle
DPG-2145-00X
*
*
2 + idle
*
DPG-2146-00X
*
*
1 + idle
DPG-2155-00X
* *
2 + idle
*
Operating Voltage Range:
9–30 Vdc *
Rated Output Current:
7 A Maximum(continuous)
Maximum Surge Current:
14 A (not to exceed ten seconds)
Connections:
Terminal strip with 7 Euro style
terminals or a quick connector with
12 pins
Input Signal from Magnetic Pickup:
2.0 VAC RMS minimum during cranking
Input Signal from Engine’s
Ignition System:
40 V minimum during cranking
Ambient Operating Temperature:
-40°F to +185°F (-40°C to +85°C)
Sealing:
Oil, water, and dust resistant via
conformal coating and die cast
enclosure
Weight:
10 oz. (284 g)
Chapter 2.
Controller Specifications
The controller’s main electrical and mechanical specifications are listed here along
with several performance characteristics. DPG-21XX-00X Series controllers are
available in five hardware configurations.
Configurations
Electrical
Woodward 2
(*) All cabling for these controllers is limited to less than 30m (98.4’).Power cabling is limited to less than 10m (32.8’) in total length.
See wiring diagrams for specific cable types required.
Mechanical
Manual 36526F DPG-21XX-00X Digital Controllers
Steady State Speed Band:
± .25% over ambient operating
temperature range
Engine Speed MPU
Measurement Range:
10 MPU Hertz to 14,000 MPU Hertz
Governing Speed Range
with MPU:
500 MPU Hertz to 11,000 MPU Hertz
Engine Speed Ignition
Measurement Range:
2 Hertz to 350 Hertz
Governing Speed Range
with Ignition:
25 Hertz to 300 Hertz
AMP 770581-1
Mini universal Mate-N-Lock
AMP 171637-3 or 794407-3
Duplex finish socket
AMP 90707-1
Crimping hand tool for 18 gauge wire
AMP 408-4137
Crimping documentation
AMP 189727-1
Socket extraction tool
Performance
Suggested Mating Connectors
for DPG-2145-00X and DPG-2155-00X Models
User Interface Operation
Keypad
The DPG-21XX-00X provides two buttons for adjusting the engine set speed.
INC – increases the selected Set Speed (A or B)
DEC – decreases the selected Set Speed (A or B)
Gain Potentiometer
The DPG-21XX-00X series controllers provide a potentiometer (labeled GAIN) to adjust
the OVG @ Set Speed A. This is one of the controller’s tuning parameters.
The gain potentiometer’s adjustment range is 1 to 99.
LED
The LED (Light Emitting Diode) is used as a status indicator. When the LED is off, it
indicates that one of the following is true:
The unit is not being powered.
The unit is reverse powered (check polarity of supplied power).
If a voltage between 9 Vdc and 30 Vdc is being properly supplied across the BAT+ and
BAT- connector pins of the controller and the LED is off, then refer to the
troubleshooting chapter.
Woodward 3
A slow blinking LED indicates all of the following:
Manual 36526F DPG-21XX-00X Digital Controllers
The COMM port is intended only for configuration and
periodic service. Do not leave a computer and/or COMM
cable connected to the COMM port.
1. The unit is powered.
2. The controller is not seeing a speed signal.
This means the engine is not running. If the engine is running or cranking and the LED
is blinking slow, then refer to the troubleshooting chapter for help in diagnosing why the
speed signal to the controller is missing.
A fast blinking LED indicates all of the following:
1. The unit is powered.
2. There is an engine speed signal at the controller’s tachometer inputs.
When the LED is on and not blinking it indicates the following:
1. The unit is powered.
2. There is a controller fault.
NOTE: The slow blink rate = ½ Hertz (the LED is turned on for 1 second followed by off
for 1 second then on again and so on). The fast blink rate is 3 times faster than the
slow blink rate.
COMM Port
All adjustments may be done by having the controller connected, via the COMM port, to
a computer running the Universal PST application. Remote access via the COMM port
is intended for connection only while programming, tuning and troubleshooting the
control. It is a service port and not intended for permanent connection.
The Universal PST is an MS Windows based application available from the Software
Products page at www.woodward.com/IC/Software. See Chapter 4 for a description of
this tool.
Woodward 4
Manual 36526F DPG-21XX-00X Digital Controllers
Chapter 3.
Parameter Reference
This chapter provides information regarding each of the parameters that can
be adjusted when a computer is connected to the controller via the COMM
port. Universal PST (described in the following chapter) is required to make
adjustments to the parameters described in this chapter, with the exception
of Set Speed A, Set Speed B, and OVG @ Set Speed A. It contains 29
subsections. Each subsection provides information about a single parameter.
The following tables list each of the parameters and their default, minimum,
and maximum values. Several of the parameters have minimum and
maximum values set by other parameters. Speed and Rate values are shown
as Hertz values.
The parameter list provides information regarding each of the parameters that
can be adjusted when a computer is connected to the controller via the COMM
port and the Universal PST software. The COMM port is intended only for
configuration and periodic service. Do not leave a computer and/or COMM
cable connected to the COMM port.
Woodward 5
Manual 36526F DPG-21XX-00X Digital Controllers
PARAMETER LIST FOR DPG-2101-00X (MPU) & DPG-2146-00X (IGNITION)
(These controllers use the 7-terminal Euro style screw terminal connector.)
PARAMETER NAME
DEFAULT
MINIMUM
MAXIMUM
Opt.
1. No. of Flywheel
Teeth or Pulses per
revolution
-001 0 0
0
-002 0 0
572
Req.
2. Set Speed A
1000 (25)
Set Speed A Min
Set Speed A Max
3. Not Available
Opt.
4. Idle Speed
50 (20)
Idle Speed Min
Idle Speed Max
Req.
5. Proportional
25 1 99
Req.
6. Integral
50 0 99
Req.
7. Derivative
25 0 99
Req.
8. OVG @ Set Speed A
Use the controller’s built-in GAIN potentiometer
9. Not Available
Opt.
10. OVG @ Idle Speed
20 1 99
Req.
11. Gain Factor
20 (40) 1 99
Req.
12. Speed Filter
16 (4) 1 24
Opt.
13. Idle Hold Time
0 0 9999
Opt.
14. Accel Rate
1000 (3000)
1
9999
Opt.
15. Decel Rate
1000 (3000)
1
9999
Opt.
16. Startup Rate
1000 (3000)
1
9999
Opt.
17. Integral Low Limit
0
0
Integral High Limit
Opt.
18. Integral High Limit
99
Integral Low Limit
99
Opt.
19. Password
0 0 99
Opt.
20. Over Speed Limit
-001
100 0 100
-002
15000 (450)
0
15000 (450)
Opt.
21. Set Speed A Min
10 (2)
10 (2)
Set Speed A
Opt.
22. Set Speed A Max
11000 (300)
Set Speed A
11000 (300)
23. Not Available
24. Not Available
Opt.
25. Idle Speed Min
10 (2)
10 (2)
Idle Speed
Opt.
26. Idle Speed Max
11000 (300)
Idle Speed
11000 (300)
Opt.
27. Duty Cycle Limit
95
10
95
Req.
28. Startup Speed
1000 (25)
10 (2)
11000 (300)
Opt.
29. Startup Duty Cycle
30 5 95
Req. = Parameter adjustment required to achieve Basic Governing
Opt. = Parameter use is optional
Default, Minimum and Maximum values in parenthesis apply when the controller uses ignition pulses to
sense engine speed, which would be the case for a DPG-2146-00X controller
DPG-2101-00X & DPG-2146-00X Parameter List
Note: All Speed and Rate values are shown as Hertz values (parameters 2, 4, 14-16, 20-22, 25-
26). Changing the value of parameter 1 will cause different default values to be displayed based
on the Hertz to RPM formula.
Woodward 6
Manual 36526F DPG-21XX-00X Digital Controllers
PARAMETER LIST FOR DPG-2155-00X (MPU) & DPG-2145-00X (IGNITION)
(These controllers use the 12-terminal quick connect.)
PARAMETER NAME
DEFAULT
MINIMUM
MAXIMUM
Opt.
1. No. of Flywheel
Teeth or Pulses per
Revolution
-001
0 0 0
-002
0 0 572
Req.
2. Set Speed A
1000 (25)
Set Speed A Min
Set Speed A Max
Opt.
3. Set Speed B
1000 (25)
Set Speed B Min
Set Speed B Max
Opt.
4. Idle Speed
50 (20)
Idle Speed Min
Idle Speed Max
Req.
5. Proportional
25 1 99
Req.
6. Integral
50 0 99
Req.
7. Derivative
25 0 99
Req.
8. OVG @ Set Speed A
Use the controller’s built-in GAIN potentiometer
Opt.
9. OVG @ Set Speed B
20 1 99
Opt.
10. OVG @ Idle Speed
20 1 99
Req.
11. Gain Factor
20 (40) 1 99
Req.
12. Speed Filter
16 (4) 1 24
Opt.
13. Idle Hold Time
0 0 9999
Opt.
14. Accel Rate
1000 (3000)
1
9999
Opt.
15. Decel Rate
1000 (3000)
1
9999
Opt.
16. Startup Rate
1000 (3000)
1
9999
Opt.
17. Integral Low Limit
0
0
Integral High Limit
Opt.
18. Integral High Limit
99
Integral Low Limit
99
Opt.
19. Password
0 0 99
Opt.
20. Over Speed Limit
-001
100 0 100
-002
15000 (450)
0
15000 (450)
Opt.
21. Set Speed A Min
10 (2)
10 (2)
Set Speed A
Opt.
22. Set Speed A Max
11000 (300)
Set Speed A
11000 (300)
Opt.
23. Set Speed B Min
10 (2)
10 (2)
Set Speed A
Opt.
24. Set Speed B Max
11000 (300)
Set Speed B
11000 (300)
Opt.
25. Idle Speed Min
10 (2)
10 (2)
Idle Speed
Opt.
26. Idle Speed Max
11000 (300)
Idle Speed
11000 (300)
Opt.
27. Duty Cycle Limit
95
10
95
Req.
28. Startup Speed
1000 (25)
10 (2)
11000 (300)
Opt.
29. Startup Duty Cycle
30 5 95
Req. = Parameter adjustment required to achieve Basic Governing
Opt. = Parameter use is optional
Default, Minimum and Maximum values in parenthesis apply when the controller uses ignition pulses to
sense engine speed, which would be the case for a DPG-2145-00X controller.
DPG-2155-00X & DPG-2145-00X Parameter List
Note: All Speed and Rate values are shown as Hertz values (parameters 2-4, 14-16, 20-26).
Changing the value of parameter 1 will cause different default values to be displayed based on
the Hertz to RPM formula.
Woodward 7
Manual 36526F DPG-21XX-00X Digital Controllers
DPG-21XX- 002 Models—Adjusting the No. of Flywheel
Teeth parameter is prohibited while the engine is
running.
EngineRPM
revperPulses
sHertz
__
60
RPM
revperPulses
sHz
1800
__132
603960
Hertz
s
revperPulsesEngineRPM
'60
__
3.1 No. of Flywheel Teeth or Pulses Per Revolution
(optional)
This parameter provides the conversion factor needed to display speeds as RPM
values instead of Hertz values. Adjusting this parameter is optional. The default value
of 0 disables Hertz (Hz) to RPM conversions so all set speeds are displayed in Hertz.
Setting this parameter to a value other than zero enables Hertz to RPM conversion.
Adjust this parameter to a value equal to the exact number of pulses seen by the
controller in one revolution of the engine to display set speeds in RPM. The formula
used to convert the speed signal from a Hertz value to a RPM value is:
For example:
The following derivation of the above formula can be used to convert from RPM to
Hertz.
DPG-2101-00X and DPG-2155-00X Models
To use this parameter correctly on controllers sensing engine speed with a magnetic
pickup, you must know the exact number of flywheel teeth that pass by the magnetic
pickup in one revolution of the engine.
DPG-2145-00X and DPG-2146-00X Models
To use this parameter correctly on controllers sensing engine speed via ignition pulses,
you must know the exact number of ignition pulses that occur in one revolution of the
engine.
3.2 Set Speed A (required)
This parameter is adjustable both from the controller’s DEC and INC keys and by using
the Universal PST application. However, when the value is changed using the
controller’s keypad, the value displayed by the Universal PST does not automatically
update. To refresh the value displayed on the PC the user must select a different
parameter with the mouse pointer then reselect the value of Set Speed A. The
Woodward 8
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